1997 SSANGYONG KORANDO section 2c

5A-202 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
KICKDOWN SWITCH
1. Separate the Kickdown Switch from the Kickdown
Switch bracket by pushing the lock.
2. Disconnect the Kickdown Switch connector.
3. Installation should follow the removal procedure in
the reverse order.
KAA5A5S0
GEAR SHIFT CONTROL LEVER
Disassembly and Assembly Procedure
1. Disconnect the negative battery cable.
2. Remove the gear shift control lever assembly.
Refer to Section 9G, interior Trim.
3. Remove the gear shift control lever knob.
4. Separate the upper and middle housing from the
gear shift control lever assembly by unlocking the
lock.
5. Remove the upper housing.
6. Disconnect the P position lamp by turning it from
the middle housing.
7. Remove the P position switches assembly bolts.
8. Remove the middle housing with the mode
selector switch wiring harness from the gear shift
control lever assembly.
9. Separate the P position switches assembly with
the P position lamp wiring harness from the gear
shift control lever assembly.
Notice: Adjust the brake transmission shift interlock
ease the operation well.
10. Remove the clips supporting the springs and
bushes from the pin of the pin of the gear shift
control lever.
11. Remover the spring and bushes from the pin of
the gear shift control lever.
12. Remove the gear shift control lever by pushing
the pin.
13. Installation should follow the removal procedure
in the reverse order.
KAA5A5P0
KAA5A5Q0
KAA5A5R0

SECTION 5B
MANUAL TRANSMISSION
TABLE OF CONTENTS
General Description and Operation.....................5B-2
Shift Lever...........................................................5B-2
Transmission Assembly.......................................5B-2
Specifications......................................................5B-3
Diagnostic Information and Procedures..............5B-4
Diagnosis Table...................................................5B-6
Component Locator............................................5B-7
Cross-Sectional View ...........................................5B-7
Power Flow..........................................................5B-8
Seni-Remote Kit Disassembly and Assembly.......5B-9
Transmission Assembly.....................................5B-10
Transmission Assembly Disassembled View......5B-11Maintenance and Repair................................... 5B-14
On-Vehicle Service...............................................5B-14
Semi-Remote Kit................................................5B-14
Transmission.....................................................5B-19
Unit Repair.......................................................... 5B-24
Major Unit..........................................................5B-24
Main Shaft.........................................................5B-34
Input Shaft........................................................5B-38
Counter Shaft....................................................5B-40
Extension Housing.............................................5B-40
Shift Cover........................................................5B-41
Inspection of Components.................................5B-45

MANUAL TRANSMISSION 5B-7
SSANGYONG MY2002
COMPONENT LOCATOR
CROSS-SECTIONAL VIEW
YAD5B040
1 4th Gear
2 3rd-4th Synchronizer
3 3rd Gear
4 2nd Gear
5 1st-2nd Synchronizer
6 Reverse Gear7 1st Gear
8 5th Gear
9 5th Synchronizer
10 Counter Shaft
11 Reverse Idler

Specifications.......................................................5C-2
General Specifications.........................................5C-2
Fastener Tightening Specifications.......................5C-2
Component Locator.............................................5C-3
Clutch Assembly.................................................5C-3
Pedal and Master Cylinder...................................5C-4
Maintenance and Repair.....................................5C-5
On-Vehicle Service.................................................5C-5
Bleeding of Clutch System...................................5C-5
Clutch Disc......................................................... 5C- 6
Master Cylinder.................................................5C-10Clutch Pedal...................................................... 5C-12
Clutch Oil Chamber........................................... 5C-14
Diagnosis............................................................ 5C-15
Clutch Slips....................................................... 5C-15
Poor Disengagement ......................................... 5C-15
Hard to Shift or Will not Shift............................... 5C-15
Clutch Chatters When Starting........................... 5C-15
Difficult Pedal Operation.................................... 5C-16
Clutch Noisy...................................................... 5C-16
Special Tools and Equipment............................ 5C-17
Special Tools Table............................................ 5C-17
SECTION 5C
CLUTCH
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.
TABLE OF CONTENTS

SECTION 5D1
TRANSFER CASE (TOD)
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
other-wise noted.
TABLE OF CONTENTS
Description and Operation.................................5D1-2
Torque on Demand (TOD) System
Transfer Case.................................................5D1-2
Transfer Case Control Unit (TCCU).....................5D1-2
TCCU Coding....................................................5D1-2
Pin Description..................................................5D1-3
Components of the TOD Transfer Case System ..5D1-4
Definition of Terminology....................................5D1-4
Operation of the TOD Transfer Case System......5D1-4
Component Locator...........................................5D1-7
Torque on Demand (TOD) Type Transfer Case....5D1-7
Transfer Case Disassembled View.....................5D1-8
TOD Control Unit..............................................5D1-10
Diagnosis..........................................................5D1-11
Self-Diagnostic Tests.......................................5D1-11
Diagnostic Trouble Codes (DTCs)....................5D1-12
Clearing Diagnostic Trouble Codes..................5D1-12
4WD Check Indicator Stays on with Ignition
Switch ON....................................................5D1-14
4WD Low Indicator Stays on with Ignition
Switch ON....................................................5D1-16
No 4WD Check or 4WD Low Indicator with
Ignition Switch ON........................................5D1-18
4WD Low Indicator Blink Steadily.....................5D1-20
TCCU Diagnostic System Check......................5D1-21
DTC 1714 Eeprom Checksum Fault..................5D1-22
DTC 1715 Tp Sensor Loss of Signal.................5D1-24
DTC 1716 Tp Sensor Out of Range...................5D1-26
DTC 1721 Electromagnetic Clutch Open / Short
to Battery.....................................................5D1-28
DTC 1722 Electromagnetic Clutch Short to
Ground.........................................................5D1-32
DTC 1731 Front Speed Sensor Voltage Low......5D1-36
DTC 1732 Front Speed Sensor Voltage High.....5D1-38DTC 1733 Rear Speed Sensor Voltage Low......5D1-40
DTC 1734 Rear Speed Sensor Voltage High.....5D1-42
DTC 1735 Speed Sensor Reference Voltage
Low ..............................................................5D1-44
DTC 1736 Speed Sensor Reference Voltage
High.............................................................5D1-46
DTC 1741 Motor Output Open / Shorted
to Battery.....................................................5D1-48
DTC 1742 Motor Output Shorted to Ground......5D1-52
DTC 1743 Shift System Timeout.......................5D1-55
DTC 1750 General Position Encoder Fault
(Invalid Code)...............................................5D1-56
DTC 1751 Position 1 Shorted to Ground............5D1-58
DTC 1752 Position 2 Shorted to Ground............5D1-60
DTC 1753 Position 3 Shorted to Ground............5D1-62
DTC 1754 Position 4 Shorted to Ground............5D1-64
Repair Instructions............................................5D1-66
On-Vehicle Service.............................................5D1-66
Oil Replacement..............................................5D1-66
Transfer Case Control Unit (TCCU)...................5D1-67
Transfer Case..................................................5D1-67
Shift Motor.......................................................5D1-69
Front and Rear Propeller Shaft Speed Sensor ...5D1-70
Unit Repair........................................................5D1-71
Transfer Case Overhaul...................................5D1-71
Specifications...................................................5D1-79
General Specification.......................................5D1-79
TCCU Electric Characteristics..........................5D1-79
Fastener Tightening Specifications...................5D1-79
Schematic and Routing Diagram....................5D1-80
TOD Transfer Case Control Unit (TCCU)............5D1-80
Special Tools and Equipment..........................5D1-82
Special Tool Table ...........................................5D1-82

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:

TRANSFER CASE 5D1-67
SSANGYONG MY2002
KAA5D260
KAA5D270
TRANSFER CASE CONTROL UNIT
(TCCU)
Removal and Installation Procedure
1. Turn the ignition switch to OFF.
2. Disconnect two connectors from the TCCU under
the driver seat.
3. Remove two bolts and the TCCU.
Installation Notice
Tightening Torque 10 Nm (7 lb-ft)
When replacing the TCCU, it is required to a
cod-ing correspondent with the vehicle
specification. Refer to “TCCU Coding” in this
section.
4. Installation should follow the removal procedure
in the reverse order.
TRANSFER CASE
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Lift the vehicle and make sure safety.
Notice: Be careful not to touch the catalytic
converter which is very hot after driving or engine
running.
3. Remove the drain plug and drain the transfer case
oil. Refer to “Oil Replacement” in this section.
Installation Notice
4. Disconnect the transmission extension wiring con-
nector on backside of transfer case.
5. Disconnect shift motor and clutch coil connector
(black 7 pin) on upper backside of transfer case.
6. Disconnect front and rear speed sensor connector
(white 7 pin).
7. Disconnect speedometer sensor connector.
Tightening Torque19 - 30 Nm
(14 - 22 lb-ft)

TRANSFER CASE 5D1-71
SSANGYONG MY2002
KAA5D360
KAA5D330
KAA5D380
UNIT REPAIR
TRANSFER CASE OVERHAUL
Disassembly Procedure
1. Remove the transfer case assembly. Refer to
“Transfer Case” in this section.
2. Disassemble the white 7 pin connector of propeller
shaft speed sensor and separate the pin
connected to brown wire to clutch coil.
3. Remove the propeller shaft speed sensors with
wires. Refer to “Front and Rear Propeller Shaft
Speed Sensor” in this section.
4. Remove vehicle speed sensor. Refer to Section
1F, Engine Control.
7. Remove the bolts that retain the front case to the
rear cover.
Notice:
Make sure that the front case is facing
downward so that the rear cover is facing
upwards.
Pry on the bosses and separate the front case
from the rear cover.
Remove all traces of gasket sealant from the
mating surfaces of the front case and rear cover. 5. Remove shift motor/clutch coil. Refer to “Shift
Motor and Clutch Coil” in this section.
Notice: When removing shift motor, pay attention
to the location of triangular slot and shaft in
transfer case inside motor and mark the position.
6. Using a 30 mm thin-wall socket, first remove the
rear output shaft nut, rear output shaft yoke
washer, oil seal then the rear output shaft flange.