1998 SSANGYONG MUSSO Workshop Repair Manual

5C-16 CLUTCH
Inspection Procedure
1. Pedal Stroke (A).
Notice
To adjust the pedal stroke, loosen the lock nut (H) of the
interlock switch (G) and turn the two lock auto until the stroke
is correct.
Max. Stroke 158 mm
2. Pedal Height (B).
Notice
To adjust the pedal height, loosen the lock nut (C) of the
stopper bolt(D) and turn the stopper bolt until the height is
correct.
Height (From the Floor Carpet) 147 - 187 mm
3. Pedal Free Play (E).
Notice
To adjust the pedal free play, loosen the lock nut (F) of the
master cylinder and turn the push rod until the free play is
correct.
4. Check the fulcrum pin and the bushing for wear, the pedal
for bending and the spring for damage.
Free Play 5 - 10 Nm

CLUTCH 5C-17
CLUTCH OIL CHAMBER
1 Clutch Master Cylinder
2 Hydraulic Tube
3 Bolt4 Clutch Oil Chamber
5 Hydraulic Tube
6 Clutch Release Cylinder
Notice
lInstallation should follow the removal procedure in the reverse order.
lWhen installing, perform the bleeding procedures from chamber cylinder and release cylinder.

Model
Type
Gear Ratio
Oil
Manufacturer
WeightPart-Time 4408 (E)
E.S.O.F. Type
1 : 1
2.48 : 1
ATF S-3, S-4 or DEXRON II, III
1.2 L
Check : Every 15,000 km
Replace : Every 50,000 km
Borg Warner
30 kg
SECTION 5D1
TRANSFER CASE (PART TIME 4408)
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
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 . . . . . . . . . . . . . . . . . . . . . . . 5D1-1
General Specifications . . . . . . . . . . . . . . . . . 5D1-1
Schematic and Routing Diagram . . . . . . . . 5D1-2
Part Time Transfer Case - 4408 . . . . . . . . . . 5D1-2
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5D1-3
Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . 5D1-4
System Description . . . . . . . . . . . . . . . . . . . . 5D1-4
Self-Diagnosis Test . . . . . . . . . . . . . . . . . . . . 5D1-8Diagnostic Diagram . . . . . . . . . . . . . . . . . . . 5D1-9
Maintenance and Repair . . . . . . . . . . . . . 5D1-10
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 5D1-10
Maintenance of Transfer Case Lubricant . . 5D1-10
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-11
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
Transfer Case Control Unit (TCCU) . . . . . . 5D1-36
High
Low
Specification
Capacity
Lubrication ApplicationDescription

5D1-2 TRANSFER CASE (PART TIME 4408)
SCHEMATIC AND ROUTING DIAGRAM
PART TIME TRANSFER CASE - 4408

TRANSFER CASE (PART TIME 4408) 5D1-3
Cannot Front Wheel Drive when Shifted 4H,4L
DIAGNOSIS
Electric Shift Problems
Action
Overhaul and check, replace if necessary.
Overhaul and check for wear and damage.
Replace if necessary.
Check sliding parts, replace if necessary. Checks
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
Checks
Broken Drive ChainAction
Check sliding parts, replace if necessary.
Noise in 4WD Operation
Checks
Improper or low oil
Loosened bolts or mounted parts
Noisy T/C bearing
Noisy gearsAction
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 necessary.
Noise in 4H or 4L
Checks
Worn or Damaged Sprockets or Drive Chain
Incorrect Tire PressureAction
Disassemble and check for wear and damage, replace
if necessary.
Adjust tire pressure.
Transfer Case Oil Leakage
Action
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 Checks
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

5D1-4 TRANSFER CASE (PART TIME 4408)
SELF-DIAGNOSIS
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 the engine room 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.
lTCCU
lShift motor
lMagnetic synchronizer clutch
lSpeed sensor
lHub solenoid
lSelector switch
lMotor position sensor
3. Transfer case system is malfunctioning when:
l4H ,4L indicator lights are remain on after 0.6 second
when turning the ignition switch ‘ON’
l4H,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) 5D1-5
Defective Code Reading
1. Position the ignition switch to ‘OFF’
2. Using a service connector, connect the No.2 pin ( lgnition )
and No.6 pin (TCCU) of the diagnosis socket in the engine
room.
3. Position the ignition switch to 'ON'.
4. Read the flashing ‘4WD CHECK’ indicator light and identify
the malfunctioning part.
How to Eliminate the Falut Code
1. Position the ignition switch to ‘OFF’
2. Using a service connector, connect the No.2 pin (GND) and
No.6 pin (TCCU) of the diagnosis socket in the engine room.
3. Position the ignition switch to ‘ON’ over 5 seconds.
4. Do defective code reading and make sure that all defective
codes are eliminated.

5D1-6 TRANSFER CASE (PART TIME 4408)
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.
No.Defective Code
Malfunctioning Part
1
2
3
4
5TCCU
Shift Motor
Synchronizer Clutch
Speed Sensor
Hub Solenoid
4WD
CHECK
Light
ON
OFF
Defective Code
4WD
CHECK
Light
ON
OFF
Defective Code
4WD
CHECK
Light
ON
OFF
Defective Code
4WD
CHECK
Light
ON
OFF
Defective Code
4WD
CHECK
Light
ON
OFF
Defective Code