1997 SSANGYONG KORANDO manual transmission

SSANGYONG MY2002
5B-42 MANUAL TRANSMISSION
Install the 3-4 shift fork and its selector plate.
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Push the shift shaft through the 1-2 shift fork.
Place the selector arm and interlock plate in the
cover.
Note the position of the interlock plate and
selector arm.
Push the shift shaft through the 3-4 shift fork.

MANUAL TRANSMISSION 5B-43
SSANGYONG MY2002
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Push the shift shaft through the 3-4 shift fork.
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Install the roll pin that fixes the selector arm to
the shift shaft.
4. Check the shift cover parts for proper assembly
as follows :
Insert a pin punch (3/16) into the offset lever
hole of the shift shaft.
Place the shift cover to the flat ground and rotate
the shift shaft so that the punch is vertical.
Selector arm should be aligned with the 3/4 shift
fork selector plate.
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SSANGYONG MY2002
5B-44 MANUAL TRANSMISSION
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5. Lubricate and install the O-ring on the rear of the
shift cover.

MANUAL TRANSMISSION 5B-45
SSANGYONG MY2002
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INSPECTION OF COMPONENTS
Inspection Procedure
1. Clean all parts with solvent and dry them with
compressed air. Check the following parts for
cracks and damaged sealing surfaces.
Case
Extension housing
Shift Cover
Input bearing retainer
Counter shaft rear bearing retainer
2. Check the parts which support bearings and shafts
for excessive wear and replace them if necessary.
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3. Check the bearing surfaces of the following parts ;
Input shaft
Main shaft and its gears
Counter shaft and 5th drive gear
4. Check the reverse idler shaft and its gears.
Notice: Replace excessive wear parts and do not
file on the hardened surface and precision ground.
5. Check the shift mechanism parts as follows :
Wear of the shift shaft.
Wear of the detent/guide plate and offset lever.
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SSANGYONG MY2002
5B-46 MANUAL TRANSMISSION
8. Check the following Bearing for excessive war:
Crankshaft pilot bushing for the front of the input
shaft.
Clutch release bearing.
Input shaft bearing.
Main shaft pilot bearing rollers.
Main shaft thrust Bearing and its surfaces.
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6. Check worn edges on the following parts :
Selector arm.
Interlock plate.
Selector plates for the 1-2 and 3-4 shift forks.
5-R shift lever and the rollers on the reverse
fork and the 5th shift rail/fork.
7. Check worn mating surfaces on the following parts :
1-2 shift fork, pads and synchronizer sleeve.
3-4 shift fork, pads and synchronizer sleeve.
5th shift rail/fork pads and synchronizer sleeve.
Reverse fork and reverse idler gear sleeve.

MANUAL TRANSMISSION 5B-47
SSANGYONG MY2002
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Speed gear roller bearing on the main shaft.
Main shaft rear bearing.
Counter shaft front and rear bearings.
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9. Check the gear tooth surfaces of all gear sets.
10. Check the reverse gear set surfaces. Check the
surfaces of gear teeth for excessive wear, pitting,
scoring and spalling and replace if necessary.
11. Take apart the three synchronizer assemblies and
check :
The 1-2 synchronizer.
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SSANGYONG MY2002
5B-48 MANUAL TRANSMISSION
14. Check for gear clash on the synchronizer sleeve
teeth or the clutch teeth on the speed gear.
15. Check the synchronizer sleeve and gear clutch
tooth for hop-out.
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The 5th blocking ring.
12. Check the fit between the hub and sleeve of each
synchronizer
Excessively tight or loose hub-to-sleeve fit.
Wear of the cone clutch surfaces of brass
blocking rings and gears.
13. Measure the clearance between the blocking ring
and the speed gear
New 1-2 blocking ring : 0.87 - 1.4mm
New 3-4 blocking ring : 0.88 - 1.5mm
Notice: Excessive wear of the blocking ring or the
speed gear cone surface will cause shift block-
out gear clash.

SSANGYONG MY2002
5D1-4 TRANSFER CASE
COMPONENTS OF THE TOD
TRANSFER CASE SYSTEM
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.
Rear Speed Sensor
A hall effect speed sensor which produces a square
wave. 0 to 5 volts direct current signal in response to
a rotating 30-tooth wheel coupled to the rear propeller
shaft inside the transfer case. Each rotation of the rear
propeller shaft will result in 30 speed sensor pulse.
Front Speed Sensor
A hall effect speed sensor which produces a square
wave. 0 to 5 volts direct current signal in response to
a rotating 30-tooth wheel coupled to the front propeller
shaft inside the transfer case. Each rotation of the front
propeller shaft will result in 30 speed sensor pulse.
Electro-Magnetic Clutch
An electromagnetic clutch used to control the amount
of torque applied to the front propeller shaft.
Position Encoder
A set of 4 gray code switches which provide feedback
to the TCCU indicating the position of the shift motor.
Clutch Pedal Position Switch
A switch on vehicles equipped with a manual transmis-
sion which indicates that the clutch pedal is depressed
Park/Neutral Position Switch
A switch on vehicles equipped with an automatic trans-
mission which indicates that the transmission is in neu-
tral.
4H/4L Switch
A switch selects the desired gear ratio.
DEFINITION OF TERMINOLOGY
Shift Inhibit Speed
The vehicle speed limit, which transfer case shifts, is
disallowed. Vehicle speed is indicated by propeller
shaft speed measurement.
Duty Cycle
Duty cycle is the time the electromagnetic clutch is on
divided by the period in which it is being modulated.
Touch-off
A minimum amount of duty cycle applied to the electro
magnetic clutch.
Front Overrun
A condition where the front propeller shaft is turning at
a rate which is faster than the rear propeller shaft.
Rear Overrun
A condition where the rear propeller shaft is turning at
a rate which is faster than the front propeller shaft.
High Range
The highest (numerically lowest = 1 : 1) gear ratio be-
tween the input and outputs of the transfer case.
Low Range
The lowest (numerically highest = 2.48 : 1) gear ratio
between the input and outputs of the transfer case.
OPERATION OF THE TOD
TRANSFER CASE SYSTEM
Initial Operation of TOD Control Unit
When ignition switch is turned to ON, 4WD LOW and
4WD CHECK lamp illuminates for 0.6 second to check
bulb in instrument panel, then perform diagnosis of
system. Refer to “Self-Diagnosis Test” in this section.
Electric Shift System Operation
The electric shift system is responsible for changing
the transfer case gear ratio by controlling the electric
shift motor. The TCCU monitors the 4H/4L switch, park/
neutral position switch, speed sensors, position
encoder, and ignition switch.
A range change is initiated when:
The 4H/4L switch is changed from 4H to 4L or from
4L to 4H.
The motor position (as indicated by the position
encoder) does not match the 4H/4L switch
immediately after the ignition is turned on.
Shift Criteria
When a range change is initiated a diagnostic test will
be completed on the motor, speed sensors, and
position encoder. If the diagnostic test fails, the shift
will not be attempted. If all components are operating
properly, the TCCU will attempt a range change after
the following shift criteria are met:
The transmission is in neutral for 2 seconds after
the shift is requested.
Both propeller shaft speeds are below 87 rpm (2580
pulses/minute). If the transmission is taken out of
neutral before 2 seconds has passed, or either
propeller shaft speed increases above the limit, the
shift will be suspended and the 4L indicator will
continue to blink until the criteria are met again or
the 4H/4L switch is returned to the original position.
Range Change
When the shift criteria are met, the motor is rotated in
the appropriate direction (as determined by the selector
switch) until one of the following occurs: