Page 1385 of 2053
TRANSFER CASE 5D1-15
SSANGYONG MY2002
Step
2
3
4
5Action
Yes
Go to Step 3
System OK
Go to Step 5
System OKNo
Go to Step 4
-
System OK
- Value(s)
1. Turn the ignition switch to OFF.
2. Disconnect the 18-pin connector from transfer case
control unit (TCCU).
3. Turn the ignition switch to ON and check the 4WD
CHECK bulb operation.
Does the 4WD CHECK indicator come on steadily?
Repair any short to ground circuit between terminal
B2 of TCCU connector and terminal A4 of cluster.
Is the repair complete?
1. Turn the ignition OFF.
2. Check the pin or terminals for damage or improper
connection.
3. Reconnect all the connectors.
4. Turn the ignition ON.
Does the 4WD CHECK indicator come on steadily?
Replace the TCCU.
Is the repair complete?
Page 1386 of 2053

SSANGYONG MY2002
5D1-16 TRANSFER CASE
KAA5D040
NO 4WD LOW INDICATOR STAYS ON WITH IGNITION SWITCH ON
Circuit Description
When the ignition switch turns to ON the transfer case
control unit (TCCU) illuminates 4WD CHECK and 4WD
LOWindicator to check bulb operation and turns off
after 0.6 seconds. Then TCCU starts self-diagnosis
and illuminate 4WD CHECK indicator when TCCU
detects any fault.
Diagnostic Aids
If the 4WD LOW indicator illuminates steadily the
transfer case in 4 wheel drive low range and 4H/4L
switch set to 4L. It is normal condition.
The 4WD LOW indicator also illuminates steadily if
the terminal B9 of TCCU connector is shorted to
ground. The shorted wire or terminals should be re-
paired.
Test Description
The number(s) below refer to step(s) on the diagnostic
table.
2. This step checks for the normal bulb operation.
Step
1
2
Action Yes
Go to Step 2
System OKNo
Go to Step 3
- Value(s)
Check the position of 4H/4L switch.
Does the 4H/4L switch set on 4L.
1. Turn the ignition switch to ON.
2. Set the shift lever to N (neutral).
3. Turn the 4H/4L switch to 4H.
Does the 4WD LOWindicator go off?
Page 1387 of 2053
TRANSFER CASE 5D1-17
SSANGYONG MY2002
Step
3
4
5
6
7ActionYes
Go to Step 4
System OK
Go to Step 6
System OK
System OKNo
Go to Step 5
-
System OK
Go to Step-7
- Value(s)
1. Turn the ignition switch to ON.
2. Set the shift lever to N (neutral).
3. Turn the 4H/4L switch to 4L.
Does the 4WD LOWindicator go off?
The wiring of 4H/4L switch is reversed. Repair the
wiring.
Is the repair complete?
1. Turn the ignition OFF.
2. Check the pin or terminals for damage or improper
connection.
3. Reconnect all the connectors.
4. Turn the ignition ON.
Does the 4WD LOW indicator come on steadily?
Repair any short to ground circuit between terminal B9
of TCCU connector and terminal A8 of cluster.
Is the repair complete?
Replace the TCCU.
Is the repair complete?
Page 1388 of 2053
SSANGYONG MY2002
5D1-66 TRANSFER CASE
KAA5D240
KAA5D250
ON-VEHICLE SERVICE
OIL REPLACEMENT
Important: Use only recommended oil or not the trans-
fer case will be severely damaged. Inspect every
10,000 km and replace every 60,000 km.
Specified Oil Level
The oil level should be just under the filler hole.
REPAIR INSTRUCTIONS
Oil Replacement
1. Lift the vehicle and make sure safety.
2. Prepare a vessel to drain transfer case oil.
3. Remove the planner damper, if equipped.
4. Remove the drain plug and filler plug, and drain
the oil completely.
5. Install and tighten the drain plug.
Installation Notice
6. Replenish recommended transfer case oil to speci-
fied oil level through the filler plughole.
7. Install and tighten the filler plug.
Installation Notice
8. Check oil leakage.
9. Install the planner damper.
Installation Notice
Tightening Torque19 - 30 Nm
(14 - 22 lb-ft)
Tightening Torque4 - 6 Nm
(35 - 53 lb-in)
Tightening Torque29 - 41 Nm
(21 - 30 lb-ft)
Page 1389 of 2053

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)
Page 1390 of 2053
SSANGYONG MY2002
5D1-68 TRANSFER CASE
KAA5D280
KAA5D290
KAA5D300
KAA5D310
8. Disconnect breather hose on the front upper side
of the transfer case near front propeller shaft.
12. Remove five bolts that connect transfer case and
transmission adapter housing.
Installation Notice 11. Remove 4 bolts that connecting the rear propeller
shaft and rear output shaft flange.
Installation Notice 9. Prepare a hydraulic jack and support the transfer
case assembly.
10. Remove 4 bolts that connecting the front propeller
shaft and front output shaft/flange.
Installation Notice
Make sure the connecting surface is clean.
Apply long life grease inside transfer case input
shaft.
13. Installation should follow the removal procedure
in the reverse order.
Tightening Torque81 - 89 Nm
(60 - 66 lb-ft)
Tightening Torque81 - 89 Nm
(60 - 66 lb-ft)
Tightening Torque38 - 52 Nm
(28 - 38 lb-ft)
Page 1391 of 2053

TRANSFER CASE 5D1-69
SSANGYONG MY2002
KAA5D320
KAA5D330
SHIFT MOTOR
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect shift motor and clutch coil connector
(black 7 pin) on upper backside of transfer case.
3. Remove three shift motor mounting bolts.
Installation Notice
6. Keeps the shift motor even and pull out carefully.
Notice: When removing shift motor, pay attention
to the location of triangular slot and shaft in
transfer case inside motor and mark the position.
7. Installation should follow the removal procedure
in the reverse order.
Installation Notice:
Clean the connection surface between transfer
case and shift motor.
Apply black non-acid cure silicone rubber or
equivalent to the surface.
Do not disassemble the shift motor and replace
with new one, if necessary.
Make sure the motor position to match with 4H/
4L switch selection. 4. Remove one shift motor bracket bolt.
Installation Notice
5. Loose two adjusting bolts on the shift motor if
neces-sary.
Installation Notice
Tightening Torque8 - 11 Nm
(70 - 97 lb-in)
Tightening Torque8 - 11 Nm
(70 - 97 lb-in)
Tightening Torque3 - 5 Nm
(27 - 44 lb-in)
Page 1392 of 2053

SSANGYONG MY2002
5D1-70 TRANSFER CASE
KAA5D340
KAA5D350
FRONT AND REAR PROPELLER
SHAFT SPEED SENSOR
Removal and Installation Procedure
1. Disconnect negative battery cable.
2. Disconnect front and rear speed sensor connector
(white 7 pin).
3. Remove shift motor. Refer to “Shift Motor” in this
sec-tion.
4. Remove front and rear propeller shaft speed
sensor retaining bolts.
Installation Notice
6. Disassemble the connector of front and rear
propeller shaft speed sensor.
7. Replace front or rear propeller shaft speed sensor,
as necessary.
Notice:
While replacing the speed sensor, make sure
the proper pin position.
Do not remove one wire to clutch coil in the
transfer case.
Make tidy on the wiring harness including
conduct tube.
8. Installation should follow the removal procedure
in the reverse order. 5. Remove the speed sensors by lifting up using
a tool such as flat screw drive.
Notice: Do not shock the speed sensor because
it is too sensitive at shock.
Tightening Torque3 - 6 Nm
(27 - 53 lb-in)