1997 SSANGYONG KORANDO sensor

TRANSFER CASE 5D1-77
SSANGYONG MY2002
KAA5D420
KAA5D590
23. Install the clutch coil and tighten three bolts.
Installation Notice
Caution: Do not kink or trap the wire while
seating the clutch coil to the case.
24. Install the pin on the tang end of the helical cam
into the hole in the front case.
25. Position the torsion spring tangs so that they are
pointing toward the top side of the transfer case
and just touching the high-low shift fork.
Caution: Do not bend the helical cam during
installation to the front case because of possible
damage to the pin at the tang end of the motor
shaft.
26. Install the shift rail through the high-low shift fork
and make sure that the reverse gear shift rail is
seated in the front case bore.
27. Install rear propeller shaft speed sensor toothed
wheel, vehicle speedometer gear and rear output
shaft seal if removed. Use oil seal installer or equiv-
alent.
Tightening Torque8 - 11 Nm
(6 - 8 lb-ft)

SSANGYONG MY2002
5D1-78 TRANSFER CASE
31. Install the rear output shaft flange on rear output
shaft. Install the rubber seal, output shaft yoke
washer and nut. Tighten the nut and calk the nut
on the flat area.
Installation Notice
32. Install the shift motor. Refer to the “Shift Motor”
in this section.
33. Insert the brown wire and pin to speed sensor con-
nect and assemble the connector. Refer to “Front
and Rear Propeller Shaft Speed Sensors” in this
section.
34. Install the drain plug and tighten the drain plug.
Installation Notice
35. Fill the transfer case with 1.4 liters of ATF or equiva
lent.
Notice: Fluid level should be just below the filler
plug-hole.
36. Install the filler plug and tighten.
Installation Notice
37. Install the transfer case to the vehicle. Refer to
“Transfer Case” in the section.
5D380
28. Coat the mating surface of the front case with a
bead of black non-acid cure silicone rubber or
equivalent.
29. Assemble the rear case on to front case.
Notice: Align the rear output shaft with the rear
case output shaft bore. Align the helical cam with
the rear case motor bore.
30. Install the bolts retaining the case halves and
tighten the bolts.
Installation Notice
Tightening Torque27 - 35 Nm
(20 - 26 lb-ft)
Tightening Torque140 - 200 Nm
(103 - 148 lb-ft)
Tightening Torque19 - 30 Nm
(14 - 22 lb-ft)
Tightening Torque4 - 6 Nm
(35 - 53 lb-in)

SSANGYONG MY2002
5D2-10 TRANSFER CASE (PART TIME - 4408)
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
Faulty or damaged TCCU, speed
sensor, motor, clutch or internal wirings
Damaged or worn shift cam, hub, fork
and rail shift
Binding shift fork, hub collar or gear
Broken drive chain
Improper or low oil
Loosened bolts or mounted parts
Noisy T/C bearing
Gear abnormal noise
Worn or damaged sprockets or drive
chain
Incorrect tire pressure
Cracked transfer case
Leakage from other parts
Breather clogging
Improper or too much oil
Loosened sealing bolts
Improperly applied sealant
Worn or damaged oil seal
Overhaul and check, replace if neces-
sary.
Overhaul and check for wear and
damage.
Replace if necessary.
Check sliding parts, replace if neces-
sary.
Drain and replace with specified oil.
Retighten as specified.
Disassemble bearings and parts and
check for wear or damage. Replace if
necessary.
Check for wear and damage including
speedometer gear, replace if neces-
sary.
Disassemble and check for wear and
damage, replace if necessary.
Adjust tire pressure.
Replace the case.
Clean case and parts and check for
leakage.
Remove breather hose and clean,
replace if necessary.
Use specified oil and adjust oil level.
Retighten
Use specified sealant and retighten.
Replace Check Symptoms
Electric shift problems
Cannot front wheel
drive when shifted 4H,
4L
Noise in 4WD opera-
tion
Noise in 4H or 4L
Transfer case oil
leakage
Action

TRANSFER CASE (PART TIME - 4408) 5D2-11
SSANGYONG MY2002
KAA5D080
KAA5D090
KAA5D100
SELF-DIAGNOSIS TEST
System Description
1. TCCU detects transfer case system malfunctions
and indicates malfunctioning part(s) through
flashing 4H, 4L indicator lights.
Using a service connector, connect it to the
diagnosis box in under instrument pannel and read
the flashing of the “4WD CHECK” indicator light.
The flashing indicator light will show you defective
code(s).
2. Identify 7 defective codes after reading the
flashing indicator light.
TCCU
Shift motor
Magnetic synchronizer clutch
Speed sensor
Hub solenoid
Selector switch
Motor position sensor
KAA5D110
3. Transfer case system is malfunctioning when:
4H, 4L indicator lights are remain on after 0.6
second when turning the ignition switch ON.
4H, 4L indicator lights are continuously come
on during driving.
4. If only 1 part is malfunctioning, 4WD CHECK
indicator light will display defective code 3 times
continuously.
5. If more then 2 part is malfunctioning, the first
malfunctioning part will be displayed 3 times and
following malfunctioning parts will be displayed .
6. To read defective code, connect the service
connector and turn the ignition switch ‘ON’.
7. After repairing, eliminate the defective code stored
in the TCCU.
Notice: Before replacing the malfunction parts with
defective code, check the wires and connectors
for proper condition.

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
5D2-14 TRANSFER CASE (PART TIME - 4408)
4WD CHECK
Light
ON
OFF
4WD CHECK
Light
ON
OFFSelector Switch
Motor Position Sensor Defective Code No.
6
7
Malfunctioning Part
KAA5D190
KAA5D200

TRANSFER CASE (PART TIME - 4408) 5D2-19
SSANGYONG MY2002
1 Transfer Case
2 Spring Washer
3 Oil Seal
4 Companion Flange
5 Shift shaft
6 Oil Seal
7 Pipe Plug
8 Screw
9 Bolt
10 Speed Sensor and Harness Bracket
11 Speed Sensor Assembly
12 Speed Sensor
13 O-Ring
14 Locking Clip
15 Connector
16 Motor Assembly
17 Oil Seal
18 Bearing
19 Bolt
20 Pump Assembly
21 Output Shaft Assembly
22 Bearing
23 Ring Gear
24 Cover Assembly
25 Nut
26 Snap Ring
27 Bearing
28 Needle Bearing
30 Clutch Coil Assembly
31 Speed Gear
32 Oil Seal
33 Return Spring
34 Magnet
35 Clutch Housing
36 Snap Ring (option)
37 Snap Ring
38 Lock-up Hub
39 Sleeve Return Spring
40 Lock-up Collar41 Rail Shaft
42 Lock-up Fork
43 Snap ring
44 Spacer
45 Driven Sprocket
46 Driving Sprocket
47 Drive Chain
48 Nut
49 Gasket
53 Spring Pin
54 Hose Clamp
55 Hose Coupling
56 Oil Strainer
58 Reduction Hub
59 Shift Fork Assembly
60 Shift Fork Facing
61 Roller and Retainer
66 Nut
67 Plane Washer
68 Oil Seal
71 Spacer
72 Front Output Assembly
73 Breather
74 Bolt
75 Front Adapter Assembly
76 Snap Ring
80 Snap Ring
81 Bearing
82 Input Shaft Assembly
83 Sleeve Assembly
84 Needle Bearing
86 Thrust Washer
87 Retaining Ring
88 Thrust Plate
89 Sun Gear
90 Gear Carrier Assembly
97 Electric Shift Cam
99 Spacer

SSANGYONG MY2002
5D2-26 TRANSFER CASE (PART TIME - 4408)
KAA5D420
KAA5D430
3. Remove the clutch coil wiring from the connector.
4. Remove the clutch coil assembly mounting nut.
KAA5D440
KAA5D450
5. Remove the snap ring and pull out the ball bearing
from the cover to remove the speed gear.
6. Remove the clutch coil assembly and the oil seal
from the cover.
7. Remove the speed sensor and the O-ring from
the case cover.