1998 SSANGYONG MUSSO Workshop Repair Manual

5D2-50 TRANSFER CASE (TOD)
19. Install wave spring, insulator washer and armature. (Three
offset slots must align with housing to be installed)
Notice
Three slots on the thrust washer must be aligned with the
three tabs on the clutch pack housing.
20. Install apply cam onto the rear output shaft, install three
balls into the apply cam, install cam and coil housing
assembly onto rear output shaft. Install thrust bearing
assembly onto output shaft.
21. If removed, drive the front output shaft ball bearing into
the rear cover bore with Front Shaft Needle Bearing
Replacer and Driver Handle.
22. If removed, install the rear output bearing in the rear case
bore. Drive the bearing into the rear case bore with Output
Shaft Bearing Replacer and Driver Handle. Make sure that
the bearing is not cocked in the bore. Install the internal
snap ring that retains the bearing to the rear case.
23. Install the clutch coil from inside the rear case until the
wire and studs extend through the cover. Install the washers
and nuts and tighten.
CAUTION
Do not kink or trap the wire while seating the clutch coil to
the case.
24. Slide the spring spacer on the camshaft and position it
beneath the drive tang. Place the torsion spring on the
camshaft. Position the first spring tang to the left of the
camshaft drive tang(View A). Wind the second spring tang
clockwise past the drive tang(View B). Push the torsion
spring and sleeve in as far as it will go (View C). This will
seat the second spring tang on the right side of the drive
tang. Install the helical cam and slide the drive tang between
the torsion spring tangs as far as it will go.

TRANSFER CASE (TOD) 5D2-51
25. Install the pin on the tang end of the helical cam into the
hole in the front case. Position the torsion spring tangs so
that they are pointing toward the top side of the transfer
case and just touching the high-low shift fork.
CAUTION
Do not bend the helical cam during installation to the front
case because of possible damage to the pin at the tang
end of the motor shaft.
26. Install the shift rail through the high-low shift fork and make
sure that the reverse gear shift rail is seated in the front
case bore.
27. Install upper and lower speed sensors into the cover. Feed
the coil wire through the upper speed sensor wire shield.
28. Install upper tone wheel, speedometer gear and rear output
seal. Use Output Shaft Seal Replacer and Driver or
equivalent to install seal.
29. Coat the mating surface of the front case with a bead of
Black Non-Acid Cure Silicone Rubber or equivalent.
30. The following procedure must be followed prior to installing
the rear case onto the front case half:
a. Align the output shaft with the rear case output shaft bore.
b. Align the helical cam with the rear case motor bore.
If difficulty is encountered with seating the rear case, tap
the rear output shaft with a sharp blow using a rubber
mallet in a direction away from the triangular shaft while
pushing down on the rear case.
Tightening Torque 25 - 37 Nm 31. Install the bolts retaining the case halves and tighten.

5D2-52 TRANSFER CASE (TOD)
32. Install shift shaft oil seal if it is not installed.
33. Using pliers equipped with soft jaws, rotate the triangular
shaft so it is aligned with the triangular slot in the transfer
case shift motor. If triangular shaft will not rotate, rotate
the rear output shaft.
34. Slightly loosen the two nuts that attach the slotted support
bracket to the end of the motor house.
35. Apply Black Non-Acid Cure Silicone Rubber or equivalent
to motor housing base and install on transfer case.
36. Install the transfer case shift motor and three bolts along
with speed sensor wire harness bracket and tighten.
Notice
The wire harness must be routed as shown to provide
clearance and to prevent the wire harness from grounding
the damper.
37. Holding the slotted support bracket tight against the motor
housing end, secure the bracket to the transfer case,
tightening the bolt with lockwasher to 8-11 Nm (72-96 lb-
in).
38. Retighten the two nuts that attach the slotted support
bracket to the end of the motor.
39. Install the clutch coil wire terminal and sensor wires.

TRANSFER CASE (TOD) 5D2-53
40. Install the rear case flange on the output shaft. Install the
rubber seal, output shaft yoke washer and nut. Tighten
the nut.
Tightening Torque 137 - 196 Nm
41. Install the drainplug and tighten.
42. Fill the transfer case with 1.4 liters of Automatic
Transmission Fluid or equivalent.
Notice
Fluid level should be just below the filler plug hole.
Tightening Torque 19 - 30 Nm
Tightening Torque 19 - 30 Nm 43. Install the fill pulg and tighten.
44. Install the transfer case as outlined in removal and
Installation, transfer case in the section.
Notice
Make sure proper drain and fill plugs are installed if case
is replaced.

Application
Steering Wheel
Steering Gear Box
Oil Pump
Steering Column
Minmum Turning Radius
Oil
SECTION 6A
POWER STEERING SYSTEM
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6A-1
General Specifications . . . . . . . . . . . . . . . . . . 6A-1
Fastener Tightening Specifications . . . . . . . . . 6A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Hard Steering . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Steering Pulls to One Side . . . . . . . . . . . . . . . 6A-2
Excessive Wheel Play . . . . . . . . . . . . . . . . . . . 6A-2
Poor Return of Steering Wheel . . . . . . . . . . . . 6A-2
Steering Wheel Shimmy . . . . . . . . . . . . . . . . . 6A-3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Abnormal Noise From Steering System . . . . . 6A-3
Component Locator . . . . . . . . . . . . . . . . . . . 6A-4
Steering System . . . . . . . . . . . . . . . . . . . . . . . 6A-4
Maintenance and Repair . . . . . . . . . . . . . . . 6A-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 6A-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5
Oil Pump Pressure Check . . . . . . . . . . . . . . . . 6A-6
Bleeding of Power Steering System . . . . . . . . 6A-6
Steering Gear Box . . . . . . . . . . . . . . . . . . . . . 6A-7
Number of Spoke
Outer Diameter
Type
Gear Ratio
Inner Steering Angle
Outer Steering Angle
Type
Maximum Pressure
Upper Tilting Angle
Lower Tilting Angle
Type
Capacity
Change Interval
Description
4
396 mm
Rack and Pinion
¥
33°37'
31°50'
Vane
75-82 kg/cm
2
4.646°
6.969°
5.25m
ATF DEXRON II
1 L
Every 24,000 km
FASTENER TIGHTENING SPECIFICATIONS
Application
Steering Shaft Bolt
Pressure Hose Bolt
Return Pipe Nut
Slotted Nut
Steering Gearbox BoltNlm
30 - 40
12 - 18
12 - 18
35 - 45
35 - 45

6A-2 POWER STEERING SYSTEM
Checks
Damaged or Binding Steering Ball Joint
Improper Preload of Steering Pinion
Damaged Wheel or Tire
Faulty Suspension SystemChecks
Worn Steering Gear
Worn or Damaged Steering Ball Joint
Loosened Steering Gearbox BoltsChecks
Damaged Steering Linkage
Damaged Wheel and Tire
Faulty Brake System
Faulty Suspension SystemChecks
Lack of Lubrication
Abnormal Wear or Binding of Steering Ball Joint
Damaged or Faulty Steering Gear
Improper Preload of Steering Pinion
Faulty Steering Shaft Joint
Steering Fluid Leaks
Lack of Fluid or Air-in System
Faulty Steering Oil Pump
Damaged or Loosened Pump Drive Belt
Clogging Oil Line
Damaged Wheel or Tire
Faulty Suspension System
DIAGNOSIS
HARD STEERING
Action
Lubricate
Replace
Replace gear assembly
Adjust
Replace
Repair or replace
Replenish or bleed
Replace
Adjust or replace
Repair or replace
Repair or replace
Repair or replace
STEERING PULLS TO ONE SIDE
Action
Repair
Repair or replace
Repair or replace
Repair or replace
EXCESSIVE WHEEL PLAY
Action
Replace gear assembly
Replace
Retighten
POOR RETURN OF STEERING WHEEL
Action
Replace
Replace gear assembly
Repair or replace
Repair or replace

POWER STEERING SYSTEM 6A-3
Checks
Loosened Steering Gearbox Mounting Bolt
Faulty Steering Gear
Steering Column Linterference
Loosened Steering Linkage
Damaged or Loosened Oil Pump Drive Belt
Loosened Oil Pump Bracket
Loosened Oil Pump Mounting Bolt
Air-in System
Faulty Oil PumpChecks
Damaged Steering Linkage
Loosened Steering Gearbox Mounting Bolt
Damaged or Binding Steering Ball Joint
Worn or Damaged Front Wheel Bearing
Damaged Wheel or Tire
Faulty Suspension System
STEERING WHEEL SHIMMY
Action
Replace
Retighten
Replace
Replace
Repair or replace
Repair or replace
ABNORMAL NOISE FROM STEERING SYSTEM
Action
Retighten
Replace gear assembly
Replace
Retighten
Adjust or replace
Retighten
Retighten
Bleed
Replace

6A-4 POWER STEERING SYSTEM
1 Steering Wheel
2 Steering Column Shaft
3 Steering Gear Box
4 End Ass'y - Tie Rod
COMPONENT LOCATOR
STEERING SYSTEM
5 Lower Shaft
6 Oil Reservoir
7 Oil Pump
8 Steering Knuckle