1997 SSANGYONG KORANDO 5D2-1

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
5D2-10 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.

SSANGYONG MY2002
5D2-12 TRANSFER CASE (PART TIME - 4408)
KAA5D120
KAA5D130
Defective Code Reading
1. Position the ignition switch to OFF.
2. Using a service connector, connect the diagnosis
socket under instrument pannel.
3. Position the ignition switch to ON.
4. Read the flashing 4WD CHECK indicator light and
identify the malfunctioning part (See Diagnosis
Table).
How to Clear the Fault Code
1. Position the ignition switch to OFF.
2. Using a service connector, connect the diagnosis
socket in under instrument pannel.
3. Position the ignition switch to ON over 5 seconds.
4. Do defective code reading and make sure that all
defective codes are eliminated.

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

SSANGYONG MY2002
5D2-16 TRANSFER CASE (PART TIME - 4408)

y y

yyyyy yyyyy

yy yy
yy yy



yyyyyy yyyyyy
yyyyyy
yyyyyy


yyyy yyyy
yyyy




yyy yyy
yyy
yyy
yyy

yyyyyy yyyyyy yyyyyy

y y

yyyyy yyyyy yyyyy
yy
yyyy
yy yy
y
y y
yy
yy


yy yy
yy
yy yy
yyy
y
y y

y y yy
yy
yy

yyy yyy y y
yy yy
yy

yy yy
y

yy yy


yy yy
yy
yyyy
yyyyyyyyyy yyyyyyyyyy

yy yy
yy yy
y y

yy yy yy

yy yy

yyy yyy
y

y y
yy yy yy

yyy yyy
y y
yy
yy yy yy
yy yy yy y
yy yy


yy yy
yy

y
y


yyy yyy
yyy yyy
yyyyyyy
y
y
yy
yy yy
yy yy
yy




yyyyy yyyyy
yyyyy
yyyyy
yyyyy
yyyyy

yy yy

yy yy
y y
y

yy yy
y y

yy yy

yy yy
y y
COMTONENT LOCATOR
CROSS SECTIONAL VIEW
KAA5D250

TRANSFER CASE (PART TIME - 4408) 5D2-17
SSANGYONG MY2002
TRANSFER CASE ASSEMBLY
KAA5D260
1 Rear Companion Flange
2 Case Cover
3 Front Companion Flange
4 Breather Plug
5 Transfer Case
6 Input Shaft
7 Mounting Bolt8 Transmission Extension Housing
9 Bolt
10 Washer
11 Front Propeller Shaft
12 Bolt
13 Washer
14 Rear Propeller Shaft