1998 SSANGYONG MUSSO Workshop Repair Manual

TRANSFER CASE (PART TIME 4408) 5D1-31
Lockup Shift
1. Install the lockup hub and return spring to the lockup collar
and insert the snap ring.
2. Install the rail shaft through reduction shift fork assembly
previously installed and into the blind hole in case.
3. Engage the lockup fork into the 2WD/4WD groove and
check operation.
4. Install the shift collar hub to the output shaft spline.
5. Install the previously assembled electric shift cam and
assemble the clutch housing as follows.
lRotate the shift cam assembly to right so that the end of
the torsion spring contacts with reduction shift fork side.
lHolding the rail shaft, lift up the fork assembly slightly.
Adjust electric shift cam assembly so that the roller on
reduction shift fork assembly is in groove in shift cam
and button on lockup fork is on cam end.
lInstall the clutch housing over shift collar hub and insert
the retaining ring into the clutch collar hub groove.
30 Retaining Ring
31 Clutch Housing
32 Shift Collar Housing
33 2WD/4WD
Lockup Assembly
34 Snap Ring
38 Rail Shaft
39 Lockup Fork
59 Reduction Shift Fork Assembly
100 Electric Shift Cam
101 Torsion Spring35 Lockup Hub
36 Return Spring
37 Lockup Collar
38 Rail Shaft
39 Lockup Fork
55 Output Shaft

5D1-32 TRANSFER CASE (PART TIME 4408)
Cover
1. Position the cover to be the open end up on the work table.
2. Position the end of needle bearing to be identification mark
up and press into the cover until upper end of bearing is
40.47 - 40.97mm below cover face that contacts with transfer
case.
3. Press the ball bearing into the cover and install the snap
ring .
4. Install remaining parts as follows.
lInstall the 4 O-rings on the stud bolts of the clutch coil
assembly.
lInstall the clutch coil assembly inside the cover and
tighten 3 nuts.
18 Oil Seal
19 Bushing
20 Nut
21 Clutch Coil Assembly
22 Snap Ring
23 Ball Bearing
24 Needle Bearing
25 Cover
Tightening Torque 8 - 11 Nm
lInstall the bearing and motor bearing into the cover.

TRANSFER CASE (PART TIME 4408) 5D1-33
4. Install the cover onto the transfer case as follows :
lAlign the cover bores with transfer case pins.
lAlign the cover bearings with output shafts.
lAlign the cover blind hole with rail shaft and make sure
that return spring is not cocked.
29 Return Spring
38 Rail Shaft
55 Output Shaft
71 Front Output Shaft
103 Shift Shaft
109 Dowel Pin
Cover Assembly
14 Bolt
15 Wiring Clip
16 Identification Tag
17 Cover Assembly
26 Magnet
27 Speed Gear
28 Oil Seal
29 Return Spring
38 Rail Shaft
111 Case
1. Install the return spring over rail shaft in the transfer case.
2. Insert the magnet into the transfer case slot.
3. Apply 1.6mm bead of Loctite RTV 598 to the transfer case
mounting surface.
Notice
For installation of cover, align the transfer case with cover
not to use excessive force.
13 Motor Assembly
14 Bolt
15 Wiring Clip
16 Identification Tag
5. Tighten 9 bolts positioning identification tag and wiring clip.
6. Install the speed gear over output shaft spline in the cover
assembly.
7. Press the new oil seal into the cover assembly.
Tightening Torque 28 - 48 Nm

5D1-34 TRANSFER CASE (PART TIME 4408)
External Electric Shift
1. Align the motor with shift shaft and position the motor
assembly onto the cover.
2. Install the motor to the shift shaft and contact cover androtate
the motor clockwise direction to check correctengagement.
6 Bolt
7 Washer
8 Bolt
9 Sensor and Harness Bracket
10 Sensor Assembly
14 Speed Sensor
12 O-ring
13 Motor Assembly
25 Cover
13 Motor Assembly
103 Shift Shaft
3. Insert the 0-ring on the speed sensor speed sensor
assembly to the cover.
4. Install the bracket to the motor assembly and tighten 3bolts.
Tightening Torque 8 -11 Nm

TRANSFER CASE (PART TIME 4408) 5D1-35
Companion Flange
1. Install the 2 plugs to the cover.
2. Install the companion flange, oil seal and washer.
3. Holding the companion flange, tighten the nut.
1 Nut
2 Washer
3 Oil Seal
4 Companion Flange
5 Plug
25 Cover
Notice
Apply Loctite 262 to nut before installation.
Tightening Torque 346 - 380 Nm

5D1-36 TRANSFER CASE (PART TIME 4408)
TRANSFER CASE CONTROL UNIT
(TCCU)
System Description
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 driver’s switch operation during
driving (For the shifting between 4WD HIGH and 4WD LOW,
stop the vehicle).
1. Shifting from 2H to 4H
lPosition the transfer case switch from '2H' to '4H'.
lShifting is possible during driving.
l'4WD Hl' indicator light will turn on.
2. Shifting from 4H to 2H
lPosition the transfer case switch from '4H' to '2H'.
lShifting is possible during driving.
l'4WD Hl' indicator light will turn off.
3. Shifting between 4H and 4L
lShifting is possible when the vehicle is almost stopped
(below approx. 2 km/h), so it would be better stop the
vehicle.
lIn case of manual transmission equipped vehicle, apply
clutch pedal.
lIn case of auto transmission equipped vehicle, put the
lever position into 'N'.
lPosition the transfer case switch '4H' to '4L' or '4L' to
'4H'.
lAccording to the shifted position, indicator light will turn
on.
Notice
If there are malfunctions during shifting,'4H' or '4L' indicator
light will blink.

TRANSFER CASE (PART TIME 4408) 5D1-37
Inspection and Repair
1. 4H and 4L indicator light inspection
lWhen turn the ignition switch to "ON" position, 4H and
4L indicator light will turn on for 0.6 second and will turn
off immediately.
Notice
If indicator light does not turn on, check bulb, wiring harness
and TCCU.
2. TCCU inspection
Pin No.
Operation Condition
4H or 4L
2H
4H indicator light ON
4H indicator light OFF
2H or 4H
4L
Clutch pedal applied
Clutch pedal released
4L indicator light ON
4L indicator light OFF
Motor OFF
Motor ON
Motor OFF
Motor ON
Auto locking hub ON
Auto locking hub OFFVoltage(V)
4.75 - 5.35
0 - 0.50
< 1.00
> 11.00
4.75 - 5.35
0 - 0.50
< 0.50
> 11.00
< 1.00
> 11.00
< 1.00
> 11.00
< 1.00
> 11.00
> 11.00
< 1.00 J1 - 7
J1 - 8
J1 - 13
J1 - 14
J1 - 15
J1 - 16
J1 - 17
J1 - 23
Notice
lDC 12V for the TCCU operation should be maintained.
lIn case of J1-8 and J1-15, indicator light will turn on for 0.6
second when turn the ignition switch ON.
lIf 4H and 4L indicator lights remain turned on when turn the
ignition switch on or during driving, perform the TCCU
diagnosis.

SECTION 5D2
TRANSFER CASE (TOD)
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5D2-1
General Specifications . . . . . . . . . . . . . . . . . 5D2-1
Schematic and Routing Diagrams . . . . . . . 5D2-2
TOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-2
T.C.C.U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-3
Function Description . . . . . . . . . . . . . . . . . 5D2-4
TOD Control Unit . . . . . . . . . . . . . . . . . . . 5D2-12
Control Unit Diagram . . . . . . . . . . . . . . . . 5D2-14
TOD Control Unit . . . . . . . . . . . . . . . . . . . . 5D2-14
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-15
Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . 5D2-15
Diagnostic Trouble Codes (DTC's) . . . . . . . 5D2-17
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Length (mm)
Weight (kg)
Shift Mode
Gear Ratio
Oil
Max. Torque
High
Low
Specification
Capacity
IntervalTOD(Torque On Demand) Transfer Case (4423E)
343.0
36.6
4H and 4L
1 : 1
2.48 : 1
ATF S-3, S-4 or Dexron II, III
1.4 L
Inspect Every 15,000km, Replace Every 50,000km
550 lb
·ft ( 76kg·m)
.=.
.
=.
ApplicationDescription Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-18
Eliminate the Memorized Fault Code . . . . . 5D2-20
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-21
Maintenance and Repair . . . . . . . . . . . . . 5D2-33
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 5D2-33
TOD Control Unit . . . . . . . . . . . . . . . . . . . . 5D2-33
Transfer Case (TOD) . . . . . . . . . . . . . . . . . 5D2-34
Speed Sensor in Front and Rear
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . 5D2-38
Replacement of Oil . . . . . . . . . . . . . . . . . . . 5D2-40
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 5D2-41
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D2-41