1998 SSANGYONG MUSSO oil

CLUTCH 5C-11
5. Unscrew the bolts and remove the clutch cover, pressure
plate and clutch disc.
Notice
Be careful not to drop the pressure plate and clutch disc.
Installation Notice
Tightening Torque 21 - 27 Nm
6. Installation should follow the removal procedure in the
reverse order.
Notice
lBefore installation, clean oil and grease on the
flywheel surface.
lDo not clean the clutch disc and release bearing in
solvent.

5C-12 CLUTCH
Inspection Procedure
1. Clutch Cover
lCheck the diaphragm spring tip for wear and height
unevenness.
lCheck the pressure plate surface for wear, crack and
discoloration.
lCheck the strap plate rivet for looseness and replace
the clutch cover if loosened.
Unevenness Limit 0.8 mm
2. Clutch Disc
lCheck the facing for rivet looseness, excessive runout,
sticks, oil and grease.
lMeasure the rivet head depth.
If out limit, replace the disc.
3. Clutch Release Bearing
lThe release bearing is permanently lubricated and
requires no cleaning.
lCheck the bearing for sticks, damage, abnormal noise,
turning drag and wear.
4. Release Fork
lIf there is abnormal wear in contact point with bearing,
replace the release fork.
Wear Limit 0.3 mm

CLUTCH 5C-13
MASTER CYLINDER
1 Snap Pin
2 Clevis Pin
3 Clevis
4 Lock Nut
5 Flange Nut...........................................30-40 Nm
6 Push Rod
7 Cylinder Body
8 Oil Pipe................................................15-18 Nm9 Clamp
10 Reservoir
11 Spring
12 Piston Assembly
13 Boot
14 Plate
15 Snap Ring
Notice
Do not disassemble the No.12.

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

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

5D1-10 TRANSFER CASE (PART TIME 4408)
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
MAINTENANCE OF TRANSFER CASE
LUBRICANT
Oil Level Check
lClean the oil level plug and surrounding area.
lRemove the oil level plug and check whether oil is drip
out or not.
lTighten the oil level plug.
Oil Change
lClean the oil level plug and surrounding area
lPlace a suitable container under the transfer case.
lRemove the oil and tighten the drain plug.
lFill the oil through the oil level plug until oil begins to
drip out.
lTighten the oil level plug.
Cautions for oil level check and plugs tightening
lDo not use an impact wrench to remove or tighten the
oil level plug or drain plug since this will damage the
threads in the transfer case.
Tightening Torque 20 - 30 Nm

5D1-12 TRANSFER CASE (PART TIME 4408)
Removal & Installation Procedure
1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the drain plug and drain the oil.
Reinstall the drain plug.
* If planar damper is installed, unscrew 4 bolts and remove
the planar damper.
Installation Notice
Tightening Torque 19 - 30 Nm
4. Remove the breather hose.
5. Disconnect the speedometer cable connector and other
cable connectors and wiring harnesses.
6. Support the transfer case with jack and remove the front
and rear propeller shafts from the transfer case.
Installation Notice
Front
Rear81 - 89 Nm
70 - 80 NmTightening Torque