1997 SSANGYONG KORANDO 4WD

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?

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?

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?

SECTION 5D2
TRANSFER CASE (PART TIME - 4408)
TABLE OF CONTENTS
General Infromation and Operation..................5D2-2
4WD Operation Overview...................................5D2-2
System Structure...............................................5D2-3
2H Mode (Rear Wheel Drive)..............................5D2-5
4H Mode (4WD Drive - High Speed)...................5D2-6
4H Mode (4WD Drive - Low Speed)....................5D2-7
System Description...........................................5D2-8
Specifications....................................................5D2-9
Diagnostic Infromation and Procedures..........5D2-10
General Diagnosis...........................................5D2-10
Self-Diagnosis Test..........................................5D2-11
Diagnostic Diagram .........................................5D2-15
Component Locator .........................................5D2-16
Cross Sectional View.......................................5D2-16Transfer Case Assembly..................................5D2-17
Disassembly and Assembly............................5D2-18
Maintenance and Repair.................................5D2-20
On-Vehicle Service.............................................5D2-20
Maintenance of Transfer Case Lubricant...........5D2-20
4H and 4L Indicator .........................................5D2-21
TCCU Inspection.............................................5D2-21
Transfer Case Assembly..................................5D2-22
TCCU..............................................................5D2-24
Unit Repair........................................................5D2-25
Disassembly Procedure...................................5D2-25
Assembly Procedure.......................................5D2-35

SSANGYONG MY2002
5D2-2 TRANSFER CASE (PART TIME - 4408)
2WD Drive (Rear
Wheel Drive)
4WD Drive (High
Speed)
4WD Drive (Low
Speed)
2WD Drive
↔ 4WD
Drive (High Speed)
2WD Drive, 4WD
Drive (High Speed)
↔ 4WD Drive (Low
Speed)
GENERAL INFORMATION AND OPERATION
4WD OPERATION OVERVIEW
Driving Type
Transferring2H
4H
4L
2H
↔ 4H
2H, 4H
↔ 4L Application
•Normal Driving on the normal road or highway, or
high speed driving
Slipped road such as snow, rainy, sand, mud etc.
Max driving force requiring condition such as
towing, rough road.
When a vehicle is driven in turning at low speed on
the paved road, a vibration and a noise may be
occurred by tight corner braking.
2WD ↔ 4WD transfer is possible below 70 km
without operating the clutch.
Manual Transmission
Transfer starts after the vehicle stops and the clutch
is applied
Automatic Transmission
Transfer starts after the vehicle stops and the shift
lever is shifted [N] position.
Notice: After the vehicle stops and the mode switch
is selected with applying the brake pedal, shifting
[N-R-N] makes the mode transfer easier.
Operation ConditionMode Position

SSANGYONG MY2002
5D2-6 TRANSFER CASE (PART TIME - 4408)
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4H MODE (4WD DRIVE - HIGH SPEED)
KAA5D030
Power Flow
Hub
Chain
Motor
Output Shaft
Front Propeller
Shaft
Transmission
Input Shaft
Rear Propeller
Shaft
Shift Cam, Rail,
Fork
Magnetic
Clutch
TCCU

TRANSFER CASE (PART TIME - 4408) 5D2-7
SSANGYONG MY2002
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4L MODE (4WD DRIVE - LOW SPEED)
KAA5D040
Power Flow
Chain
Motor
Output Shaft
Front Propeller
Shaft
Transmission
Input Shaft
Rear Propeller
Shaft
Shift Cam, Rail,
Fork
TCCU
Planetary Gear
(2.483)
Hub

SSANGYONG MY2002
5D2-8 TRANSFER CASE (PART TIME - 4408)
KAA5D050
KAA5D060
KAA5D070
1. Shifting from 2H to 4H
Position the transfer case switch from ‘2H’ to
‘4H’.
Shifting is possible during driving.
‘4WD Hl’ indicator light will turn on.
2. Shifting from 4H to 2H
Position the transfer case switch from ‘4H’ to
‘2H’.
Shifting is possible during driving.
4WD Hl’ indicator light will turn off.
SYSTEM DESCRIPTION
Transfer Case Control Unit (TCCU)
TCCU is located under the front left handed seat and
permits the vehicle to shift from two-wheel drive to
four-wheel drive (and back shift) according to drivers
switch operation during driving (For the shifting
between 4WD HIGH and 4WD LOW, stop the vehicle).
3. Shifting between 4H and 4L
Shifting is possible when the vehicle is almost
stopped (below approx. 2 km/h), so it would be
better stop the vehicle.
In case of manual transmission equipped
vehicle, apply clutch pedal.
In case of auto transmission equipped vehicle,
put the lever position into ‘N’.
Position the transfer case switch ‘4H’ to ‘4L’
or ‘4L’ to ‘4H’.
According to the shifted position, indicator light
will turn on.
Notice: If there are malfunctions during shifting,
‘4H’ or ‘4L’ indicator light will blink.