1998 SSANGYONG MUSSO torque

5D1-30 TRANSFER CASE (PART TIME 4408)
Oil Pump
1. Install the pump front cover to be the ‘TOP’ mark down and
turn the cover to be the ‘TOP’ mark up when installed in
vehicle.
2. Install the 2 pump pins and spring to the output shaft.
Notice
Flat surface of the pins must point out and align the center
line of pins and spring.
3. Connect the hose coupling to the strainer coupling and
install the strainer foot into the transfer case slot.
Notice
The hose coupling must face the pump assembly.
4. Install the pump housing to be the 'REAR' mark up and seat
the 2 pump pins inside of the pump housing by moving
pump pins inward and compressing the spring.
5. Tighten the hose to pump housing by hose clamp.
6. Position the pump rear cover to be the ‘TOP REAR’ mark
up and located at the top of transfer case when installed in
vehicle. Position the pump retainer on the cover so that tab
on the retainer is in notch in the transfer case. Apply Loctite
to the bolts and tighten the bolts with turning the output
shaft by hand to make the pump pins move freely.
45 Shaft and Pump Assembly
46 Bolt
47 Pump Retainer
48 Rear Pump Cover
49 Hose Clamp
50 Hose Coupling
54 Pump Housing
52 Pump Pin
53 Spring
54 Front Pump Cover
55 Output Shaft
56 Strainer
40 Snap Ring
41 Spacer
42 Drive Sprocket
43 Driven Sprocket
44 Drive Chain
55 Output Shaft (Rear)
71 Output Shaft (Front)
Drive Chain
1. Position the drive sprocket to the rear output shaft end and
driven sprocket to the front output shaft end.
2. Install the drive chain onto the sprocket.
3. Holding each sprocket to be the drive chain tight and parallel
with transfer case, install the drive chain assembly to the
output shafts.
4. Rotate the driven sprocket slightly to engage splines on
the front output shaft.
5. Install the spacer to the front output shaft and insert the
snap ring into the shaft groove over spacer.
Tightening Torque 4 - 8.5 Nm

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

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

5D2-4 TRANSFER CASE (TOD)
FUNCTION DESCRIPTION
lTOD System Select Mode (4H and 4L)
4H is the mode when drive normally of which gear ratio is 1:1 and 4L mode distributes power to front and rear
wheels 50:50 of which gear ratio is 2.48:1.
lTOD System Function (select 4H mode)
TOD system controls clutch mechanism to comply with rotation in front and rear propeller shaft and if its difference
exceeds the permissible range, corresponding power is distributed into front wheel through EMC (Electro-Magnetic
Clutch).
Hall effect sensor signals speed on front and rear propeller shafts going through with TOD control unit.
Transfercase clutch coil is activated by variable current on exceeding difference of speed in front and rear propeller
shafts.
lFunction of 4L Mode
When select 4L mode, EMC is locked to apply maximum torque into front and rear propeller shafts. Shift motor
rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1:1 to 2.48:1 by planetary
gear set.
lShift Motor
It locates backside transfer case, which drives rotary helical cam.
When mode select switch changes to 4L, shift fork is on position for 2.48:1 by rotation of helical cam.
lTransfer Case
TOD transfer case distributes power into front and rear axle by operation of 4H/4L switch and shift motor.
Shifting 4H to 4L, is performed towards reducing HI-LO collar by means for connection HI-LO shift fork with
output shaft in order to join with planetary gear. Torque transmits input shaft then sun gear rotating front planetary
gear. Front planetary gear join with output shaft and drives LO position.

TRANSFER CASE (TOD) 5D2-5
Definitions
Rear Speed Sensor A Hall Effect speed sensor which produces a square wave. 0-5Vdc signal in
response to a rotating 30 tooth wheel coupled to the rear propshaft inside the
Transfer Case. Each rotation of the rear propshaft will result in 30 speed sensor
pulse.
Front Speed SensorA Hall Effect speed sensor which produces a square wave. 0-5Vdc signal in
response to a rotating 30 tooth wheel coupled to the front propshaft inside the
Transfer Case. Each rotation of the front propshaft will result in 30 speed sensor
pulse.
EMC An Electromagnetic clutch used to control the amount of torque applied to the
front propshaft.
TOD
TMTorque on DemandTM.
Duty Cycle Duty Cycle is the time the EMC is on divided by the period in which it is being
modulated.
Touch-off A minimum amount of duty cycle applied to the EMC.
Front OverrunA condition where the front propshaft is turning at a rate which is faster than the
rear propshaft.
Rear Overrun A condition where the rear propshaft is turning at a rate which is faster than the
front propshaft.
High RangeThe highest (numerically lowest = 1 :1) gear ratio between the input and outputs
of the Transfer Case.
Low RangeThe lowest (numerically highest = 2.48:1) gear ratio between the input and outputs
of the Transfer Case.
4H/4L Switch A switch which selects the desired gear ratio.
Shift Motor Electric motor which changes the Transfer Case range.
Position Encoder A set of 4 Gray code switches which provide feedback to the TCCU indicating the
position of the Shift Motor.
Clutch Interlock Switch A switch on vehicles equipped with a manual transmission which indicates that
the clutch pedal is depressed.
Neutral Safety Switch A switch on vehicles equipped with an automatic transmission which indicates
that the transmission is in neutral.
Shift Inhibit Speed The vehicle speed above which Transfer Case shifts are disallowed. Vehicle speed
is indicated by propshaft speed measurement.