1997 SSANGYONG KORANDO oil

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) 5D2-19
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
5D2-20 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)

SSANGYONG MY2002
5D2-22 TRANSFER CASE (PART TIME - 4408)
KAA5D270
KAA5D280
TRANSFER CASE ASSEMBLY
1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the damper mounting bolt.
4. Remove the drain plug and drain the oil.
Reinstall the drain plug.
Installation Notice
KAA5D290
5. Remove the breather hose.
6. Disconnect the speedometer cable connector and
other cable connectors and wiring harnesses.20 - 30 Nm
(15 - 22 lb-ft)
30 - 40 Nm
(22 - 30 lb-ft)
4 - 6 Nm
(35 - 53 lb-in)
Drain Plug Tightening
Torque
Damper Tightening
Torque
Fill plug Tightening
Torque

TRANSFER CASE (PART TIME - 4408) 5D2-25
SSANGYONG MY2002
KAA5D380
KAA5D390
UNIT REPAIR
DISASSEMBLY PROCEDURE
Shift Motor Assembly
1. Separate the harness bracket.
2. Remove the shift motor mounting bolt and remove
the shift motor assembly.
KAA5D400
KAA5D410
Companion Flange
1. Holding the companion flange, remove the nut and
washer and then remove the companion flange.
2. Remove the oil seal.
3. Remove the companion flange from the case
cover.
Case Cover Assembly
1. Remove the cover mounting bolts(9), and the case
mounting bolts(5).
Notice: Identification tag has information required
for ordering replacement parts, so be careful not
to lose it.
2. Using a driver, pry and disconnect the sealant
bond of the cover and required case.

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.

SSANGYONG MY2002
5D2-28 TRANSFER CASE (PART TIME - 4408)
KAA5D500
KAA5D510
KAA5D520
KAA5D530
2WD/4WD Lock Up Assembly Component.
(37) Snap Ring
(38) Lock up Hub
(39) Return Spring
(40) Lock up Collar
4. Remove the snap ring from the front output driven
sprocket and separate the snap ring and the
spacer.
5. Remove the driving sprocket, the driven sprocket
and the driving chain from the front/rear output
shaft.
6. Remove the oil pump assembly and the magnetic
from the output shaft.

TRANSFER CASE (PART TIME - 4408) 5D2-29
SSANGYONG MY2002
KAA5D540
KAA5D550
Remove the bolt and the retainer. Separate the
output shaft and rear pump cover.
Remove the hose clamp and remove the hose
coupling cover from the pump housing.
Remove the hose clamp, the hose coupling and
the strainer.
Remove two pump pins and the spring from
the output shaft.
Separate the front pump and remove the output
shaft.
KAA5D560
Reduction Shift Parts
1. Remove the reduction hub and reduction shift fork
assembly from the case.
2. Remove the 2 shill fork facings from the shift fork
assembly.
3. To remove the roller cam and pin, cut elf the plastic
retainer when disassembling the fork assembly.
Front Output Assembly
1. Holding the companion flange, remove the nut and
washer and then remove the companion flange and
oil seal.
2. Remove the output shaft.