1997 SSANGYONG KORANDO service

TRANSFER CASE (PART TIME - 4408) 5D2-13
SSANGYONG MY2002
Diagnostic Table
Connect a service connector. If turn the ignition switch
“ON” “4WD CHECK” indicator light will come on for
0.6 second and turn off for 3 seconds and then display
a defective code 3 times continuously.
4WD CHECK
Light
ON
OFF
4WD CHECK
Light
ON
OFF
4WD CHECK
Light
ON
OFF
4WD CHECK
Light
ON
OFF
4WD CHECK
Light
ON
OFFTCCU
Shift Motor
Synchronizer Clutch
Speed Sensor
Locking Hub Solenoid Defective Code No.
1
2
3
4
5
Malfunctioning Part
KAA5D140
KAA5D150
KAA5D160
KAA5D170
KAA5D180

SSANGYONG MY2002
5D2-20 TRANSFER CASE (PART TIME - 4408)

KAA5D220
ON-VEHICLE SERVICE
MAINTENANCE OF TRANSFER
CASE LUBRICANT
1. Oil Level Check
Clean the oil level plug and surrounding area.
Remove the oil level plug and check whether
oil is drip out or not.
Tighten the oil level plug.
Installation Notice
KAA5D230
MAINTENANCE AND REPAIR
2. Oil Change
Clean the oil level plug and surrounding area
Place a suitable container under the transfer
case.
Remove the oil and tighten the drain plug.
Installation Notice
Fill the oil through the oil level plug until oil
begins to drip out.
Tighten the oil level plug.
3. Cautions for oil level check and plugs tightening
Do not use an impact wrench to remove or
tighten the oil level plug or drain plug since this
will damage the threads in the transfer case.
Tightening Torque4 - 6 Nm
(35 - 53 lb-in)
Tightening Torque20 - 30 Nm
(15 - 22 lb-ft)

SECTION 6A
POWER STEERING SYSTEM
TABLE OF CONTENTS
Description and Operation...................................6A-2
General Description.............................................6A-2
Component Locator.............................................6A-3
Diagnostic Information and Procedures..............6A-4
Power Steering System Pressure Test..................6A-4
Power Steering System Leak Test........................6A-4
Maintenance .........................................................6A-5
Bleeding the Power Steering System....................6A-5
Checking and Adding Fluid..................................6A-5Repair Instructions................................................6A-6
On-Vehicle Service.................................................6A-6
Power Steering Fluid Reservoir.............................6A-6
Power Steering Pump Hoses and Pipes................6A-7
Specifications.......................................................6A-9
General Specification...........................................6A-9
Fastener Tightening Specifications.......................6A-9
Special Tools and Equipment............................ 6A-10
Special Tools Table............................................6A-10

SSANGYONG MY2002
6A-4 POWER STEERING SYSTEM
KAA6A020
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER STEERING SYSTEM
PRESSURE TEST
Tools Required
124 589 06 21 00 Power Steering Pump Testing Unit
Check the fluid pressure as follow to trouble is in the
pump or gear unit.
Test Procedure
1. Disconnect the pressure hose from the oil pump
and connect a pressure gauge between the oil
pump and pressure hose.
2. Bleed the system. Start the engine and turn the
steering wheel form lock several times until oil
temperature is up to 50 °C.
3. Run the engine at 1,000 rpm.
4. Close the gauge valve fully, and read pressure.
The pump pressure with the valve closed should
be between 7,355 kPa to 8,041 kPa (1,067 psi to
1,166 psi).
Notice: Do not keep the valve closed for more
than 10 seconds.
5. Remove the pressure gauge and connect the pres-
sure hose.
6. Do bleeding procedure.
POWER STEERING SYSTEM
LEAK TEST
General Procedure
Inspect the following :
The power steering fluid reservoir for overfill.
Fluid for aeration and overflow.
The hoses for loose connections.
The torsion bar, stub shaft and adjuster seals for
leaks.
The component sealing surfaces for damage.
Important: Verify the exact point of the leak. The point
from which the fluid is dripping is not necessarily the
point at which the system is leaking. When service is
required, clean the leak area upon disassembly,
replace the leaking seal, check the component sealing
surfaces for damage and reset the torque bolt to
specifications required.
External Leak Check
The purpose of this procedure is to pinpoint the location
of the leak. In some cases, the leak can be easily lo-
cated, but seepage-type leaks may be harder to find.
To locate seepage leaks, use the following method:
1. With the engine off, wipe dry the complete power
steering system.
2. Check the power steering fluid level in the pump’s
reservoir. Adjust the fluid level as necessary.
Refer to “Checking and Adding Fluid” in this
section.
Notice: Do not hold the steering wheel at a stop
for any length of time as this can damage the
power steering pump.
3. Start the engine. Turn the steering wheel counter-
clockwise and clockwise from stop to stop several
times.
4. Find the exact area of the leak and repair it.

SSANGYONG MY2002
6A-6 POWER STEERING SYSTEM
KAA6A040
3. Remove the power steering fluid reservoir
mounting bolts (1).
Removal Notice:
One power steering fluid reservoir mounting bolt
(2) is located in the fluid reservoir.
Installation Notice
KAA6A030
ON-VEHICLE SERVICE
POWER STEERING FLUID
RESERVOIR
Tools Required
DW310-021Power Steering Pump Pulley Remover/
Installer
Removal and Installation Procedure
1. Remove the power steering pump. Refer to
Section 6B, Power Steering Pump.
2. Remove the power steering pump pulley nut, using
the power steering pump pulley remover/installer
DW310-021.
Installation Notice
REPAIR INSTRUCTIONS
Tightening Torque 61 Nm (44 lb-ft)
15 Nm (11 lb-ft)
18 Nm (13 lb-ft)
Tightening
TorqueBolts (1)
Bolt (2)
4. Remove the power steering fluid reservoir upward.
After installing the power steering fluid reservoir,
bleed the power steering system. Refer to
“Bleeding the Power Steering System” in this
section.
5. Installation should follow the removal procedure
in the reverse order.

SSANGYONG MY2002
6A-4 POWER STEERING SYSTEM
KAA6A020
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER STEERING SYSTEM
PRESSURE TEST
Tools Required
124 589 06 21 00 Power Steering Pump Testing Unit
Check the fluid pressure as follow to trouble is in the
pump or gear unit.
Test Procedure
1. Disconnect the pressure hose from the oil pump
and connect a pressure gauge between the oil
pump and pressure hose.
2. Bleed the system. Start the engine and turn the
steering wheel form lock several times until oil
temperature is up to 50 °C.
3. Run the engine at 1,000 rpm.
4. Close the gauge valve fully, and read pressure.
The pump pressure with the valve closed should
be between 7,355 kPa to 8,041 kPa (1,067 psi to
1,166 psi).
Notice: Do not keep the valve closed for more
than 10 seconds.
5. Remove the pressure gauge and connect the pres-
sure hose.
6. Do bleeding procedure.
POWER STEERING SYSTEM
LEAK TEST
General Procedure
Inspect the following :
The power steering fluid reservoir for overfill.
Fluid for aeration and overflow.
The hoses for loose connections.
The torsion bar, stub shaft and adjuster seals for
leaks.
The component sealing surfaces for damage.
Important: Verify the exact point of the leak. The point
from which the fluid is dripping is not necessarily the
point at which the system is leaking. When service is
required, clean the leak area upon disassembly,
replace the leaking seal, check the component sealing
surfaces for damage and reset the torque bolt to
specifications required.
External Leak Check
The purpose of this procedure is to pinpoint the location
of the leak. In some cases, the leak can be easily lo-
cated, but seepage-type leaks may be harder to find.
To locate seepage leaks, use the following method:
1. With the engine off, wipe dry the complete power
steering system.
2. Check the power steering fluid level in the pump’s
reservoir. Adjust the fluid level as necessary.
Refer to “Checking and Adding Fluid” in this
section.
Notice: Do not hold the steering wheel at a stop
for any length of time as this can damage the
power steering pump.
3. Start the engine. Turn the steering wheel counter-
clockwise and clockwise from stop to stop several
times.
4. Find the exact area of the leak and repair it.

SSANGYONG MY2002
6A-6 POWER STEERING SYSTEM
KAA6A040
3. Remove the power steering fluid reservoir
mounting bolts (1).
Removal Notice:
One power steering fluid reservoir mounting bolt
(2) is located in the fluid reservoir.
Installation Notice
KAA6A030
ON-VEHICLE SERVICE
POWER STEERING FLUID
RESERVOIR
Tools Required
DW310-021Power Steering Pump Pulley Remover/
Installer
Removal and Installation Procedure
1. Remove the power steering pump. Refer to
Section 6B, Power Steering Pump.
2. Remove the power steering pump pulley nut, using
the power steering pump pulley remover/installer
DW310-021.
Installation Notice
REPAIR INSTRUCTIONS
Tightening Torque 61 Nm (44 lb-ft)
15 Nm (11 lb-ft)
18 Nm (13 lb-ft)
Tightening
TorqueBolts (1)
Bolt (2)
4. Remove the power steering fluid reservoir upward.
After installing the power steering fluid reservoir,
bleed the power steering system. Refer to
“Bleeding the Power Steering System” in this
section.
5. Installation should follow the removal procedure
in the reverse order.

SECTION 6B
POWER STEERING PUMP
TABLE OF CONTENTS
Description and Operation...................................6B-2
General Description.............................................6B-2
Diagnostic Information and Procedures..............6B-3
Power Steering Pump Diagnosis..........................6B-3
Repair Instructions................................................6B-4
On-Vehicle Service.................................................6B-4Serpentine Accessory Drive Belt..........................6B-4
Power Steering Pump Assembly..........................6B-4
Unit Repair............................................................6B-6
Pump..................................................................6B-6
Specifications.......................................................6B-7
Fastener Tightening Specifications.......................6B-7