1998 SSANGYONG MUSSO battery

TRANSFER CASE (TOD) 5D2-35
Removal & Installation Procedure
1. Disconnect (-) cable from battery.
2. Lift on vehicle and make sure on safety.
Notice
Be careful for catalytic converter due to high temperature
after driving or engine running.
3. Prepare a vessel to drain transfer case and manual
transmission oil.
4. Release drain plug and drain transfer case and manual
transmission oil.
If planar damper is installed, unscrew 4 bolts and remove
the planar damper.
Notice
Oil drain should be along with whole transfer case
disassembly and assembly.
5. Disconnect transmission extension wiring connector back
side transfer case.
Notice
When disconnect connector, make sure on direction of
locking tab towards inside.
6. Disconnect shift motor/clutch coil connect (Black 7 pin)
connector upper backside.
7. Disconnect front and rear speed sensor connector (white
7 pin).
8. Disconnect speedometer sensor connector right upper
side.
9. Disconnect breather tube front upper side transfer case
(upper connecting point of transfer case and front
propeller).
10. Prepare hydraulic jack and support transfer case assembly.

TRANSFER CASE (TOD) 5D2-37
Replacement of Shift Motor
1. Disconnect (-) cable from battery.
2. Disconnect shift motor/clutch coil connector (black pin7)
upper backside.
3. Unscrew 3 units of shift motor mounting bolts (M10).
4. Unscrew 1unit of bracket mounting bolt (M10).
Installation Notice
Tightening Torque 9 - 11 Nm
Notice
When disconnecting shift motor and mounting bracket, it is
required to unscrew 2 units of adjusting bolts (M10) form
motor and bracket.
5. Keep shift motor even then pull rearward.
6. Clean connection surface of transfer case and shift motor.
7. If necessary, make a test by SCANNER with shift motor
assembly.
Notice
Do not disassemble shift motor. If necessary, replace by
shift motor assembly unit.
8. Applying sealant into connecting surface for new shift motor.
9. Installation should follow the removal procedure in the
reverse order. Before installation, make sure that motor
position match with mode of 4H/4L switch.
Reference
When accord position of motor with 4H/4L switch and transfer
case match position of the disconnected motor and new
one.

5D2-38 TRANSFER CASE (TOD)
SPEED SENSOR IN FRONT AND
REAR PROPELLER SHAFT
Replacement Procedure
1. Disconnect (-) cable from battery.
2. Detach shift motor assembly.
3. Disconnect front and rear speed sensor connector (white 3
pin) upper backside transfer case.
4. Disconnect speed sensor connect from locking sleeve by
pushing.
5. Disconnect wire stick cap from the detached connector.
6. Unscrew rear speed sensor mounting bolt (M10) from upper
side of rear case flange.
7. Detach sensor from transfer case by lifting up using tool.
Notice
When disconnect sensor, make sure on adequate pressure
due to sensitiveness with shock.
8. Disconnect taping from both protection tube ends that wrap
3 wires of speed sensor and 1 wire of clutch coil.
9. Disconnect tube.

SECTION 7B/C
MANUAL CONTROL /
SEMIAUTO TEMPERATURE CONTROL
HEATING, VENTILATION AND AIR
CONDITIONING SYSTEM
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise
noted.
Specifications . . . . . . . . . . . . . . . . . . . . . . 7B/C-2
Cooling Capacity . . . . . . . . . . . . . . . . . . . . 7B/C-2
Compressor . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-2
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-2
Receiver Drier . . . . . . . . . . . . . . . . . . . . . . 7B/C-2
Dual Pressure Switch . . . . . . . . . . . . . . . . . 7B/C-2
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-3
Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-3
Fastener Tightening Specifications . . . . . . . 7B/C-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-4
Defectives in Fan Motor Circuit . . . . . . . . . . 7B/C-5
Defectives in Compressor Circuit . . . . . . . . 7B/C-5
TABLE OF CONTENTS
Component Locator . . . . . . . . . . . . . . . . . 7B/C-6
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-6
Air Conditioner System . . . . . . . . . . . . . . 7B/C-8
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . 7B/C-8
Gasoline Engine . . . . . . . . . . . . . . . . . . . . . 7B/C-9
Maintenance and Repair . . . . . . . . . . . . 7B/C-10
Refrigerant Charging . . . . . . . . . . . . . . . . 7B/C-10
Condenser . . . . . . . . . . . . . . . . . . . . . . . . 7B/C-14
Receiver Drier . . . . . . . . . . . . . . . . . . . . . 7B/C-18
Compressor . . . . . . . . . . . . . . . . . . . . . . . 7B/C-21
Heater and Air Conditioner Control Box . . 7B/C-25

MANUAL & SEMIAUTO-HVAC 7B/C-5
Action
Clean oily plate using cleaning agent.
Charge battery or check for cause.
Check wire continuity
Check A/C switch and fan switch for continuity and ground.
DEFECTIVES IN FAN MOTOR CIRCUIT
Fan Motor Does Not Run
Checks
Blown fuse
Battery voltage is low
Faulty wiring
Faulty groundAction
Check for short and replace fuse.
Check battery voltage.
Check connectors’ connection.
Do not apply grease. This can cause voltage down.
Remove body painting and completely ground,
Tighten ground bolts and make sure body ground connection.
Checks
Blown resister temperature fuse
Air leakage in parts connection
Action
Replace resistor.
Check heater, cooling unit and blower for proper connection.
Fan Motor Runs in ‘4’position Only (‘3’, ‘2’, ‘1’ : Does Not Run)
Frosted Evaporator
DEFECTIVES IN COMPRESSOR CIRCUIT
Compressor Does Not Run
Checks
Faulty thermo ampAction
Frosted evaporator reduces cooling capacity.
Off compressor and maximize blowing capacity
Checks
Faulty high/low pressure
Faulty A/C relayAction
Check compressor magnet voltage supply.
A/C relay.
Checks
Oily clutch plate
Low voltage
Faulty electric connection or operation
Magnetic Clutch Slips /Idles
Checks
Clogged or blocked intake grilleAction
Clogged or blocked intake grille reduces blowing capacity.
Motor Runs With Poor Blowing
Checks
Excessive clearance between
Clutch plate and clutch coilAction
Adjust clutch clearance (0.2-0.6mm).
Magnetic Clutch Plays By Hand Only

MANUAL & SEMIAUTO-HVAC 7B/C-19
Removal & Installation Procedure
1. Disconnect the negative(-) terminal from the battery.
2. Discharge refrigerant from the system.
Notice
By connecting a manifold gauge connection hose to High/
Low pressure line, discharge the refrigerant.
3. Disconnect the inlet and outlet pipes of receiver drier.
Notice
When installing, check the O-ring and apply the compressor
oil.
Installation Notice
4. Remove the bracket bolt and then remove the receiver drier.
Installation Notice
Tightening Torque
4 - 6 Nm
5. Installation should follow the removal procedure in the
reverse order.
Tightening Torque
5 - 8 Nm

7B/C-22 MANUAL & SEMIAUTO-HVAC
Removal & Installation Procedure
1. Disconnect the negative(-) terminal from the battery.
2. Discharge refrigerant from the system.
Notice
By connecting a manifold gauge connection hose to High/
Low pressure line, discharge the refrigerant.
3. Disconnect the high / low pressure pipe and wire connectors.
Installation Notice
Notice
Before tightening, apply the compressor oil to O-ring.
Tightening Torque
20 - 30 Nm
4. Remove the mounting bolt from the compressor bracket
and remove compressor assembly.
Notice
Place the removed compressor in vertical position.
Installation Notice
5. Installation should follow the removal procedure in the
reverse order.
Tightening Torque
21 - 26 Nm

MANUAL & SEMIAUTO-HVAC 7B/C-23
Gasoline Engine
1 Low Pressure Pipe
2 High Pressure Pipe3 Compressor Bracket
4 Compressor
Removal & Installation Procedure
1. Disconnect the negative(-) terminal from the battery.
2. Discharge refrigerant from the system.
Notice
By connecting a manifold gauge connection hose to High/
Low pressure line, discharge the refrigerant.
3. Disconnect the high / low pressure pipe and wire connectors.