1998 SSANGYONG MUSSO ABS

AUTOMATIC TRANSMISSION 5A-43
Figure 4.1 - Power Flow Diagram
TORQUE CONVERTER
The torque converter (refer figure 4.2) consists of a turbine,
stator pump, impeller and a lock-up damper and piston
assembly. As in conventional torque converters, the impeller is
attached to the converter cover, the turbine is splined to the
input shaft and the stator is mounted on the pump housing via
a one way clutch (sprag).
The addition of the damper and piston assembly enables the
torque converter to ‘lock-up’ under favourable conditions. Lock-
up is only permitted to occur in third and fourth gears under
specified throttle and road speed conditions.
Lock-up is achieved by applying hydraulic pressure to the
damper and piston assembly which couples the turbine to the
converter cover, locking-up the converter and eliminating
unwanted slippage. Whenever lock-up occurs, improved fuel
consumption is achieved. Torsional damper springs are
provided in the damper and piston assembly to absorb any
engine torque fluctuations during lock-up.
Figure 4.2 - Torque Converter Cross Section

5A-88 AUTOMATIC TRANSMISSION
8. Detach the No.7 solenoid wire from the front of the case.
9. Remove the parking pawl pivot pin and the pawl and spring
from the case.
10. Remove the shaft and the rear servo lever.
11. Remove the rear servo cover and piston assembly.
12. Remove the B1R circlip, valve and spring.
13. Remove both band adjustment shims.
14. Inspect the output shaft bushing in the case and replace if
necessary.
15. Inspect cooler line fittings and replace as necessary.
16. Inspect the case for damage.
17. To remove the park rod lever: Remove the circlip from the
inner end of the pivot shaft and tap the outer end of the
shaft until it moves free from the case, then using a wide
shallow tapered drift as a wedge, drive the pin out from
the inside of the case and remove the lever and spring.
Notice
Do not remove the park rod lever unless absolutely
necessary.

MANUAL TRANSMISSION 5B-21
23. Remove the main shaft in 2 steps.
lTo remove the rear bearing outer race, push the main
shaft rearward.
lTilt and lift the main shaft from the case.
24. Remove the reverse fork and spring from the case.
25. Remove the counter shaft as follows:
lUsing a punch and hammer, pry up the lock tabs.
lUsing a 13 mm wrench or T-40 bit, remove the 4 bolts.
lRemove the retainer and shim from the case.
lPush the counter shaft rearward to remove the rear
bearing outer race.

5B-24 MANUAL TRANSMISSION
7. Install the counter shaft rear bearing outer race, shim and
retainer.
Tightening Torque
39 - 52 Nm
lUsing a punch and hammer, bend the lock tabs on the
retainer.
8. Install the following parts :
lInstall the main shaft into case.
lInstall the main shaft rear bearing outer race into the
rear of the case.
lInstall the 4th speed blocking ring onto the front of the
main shaft.
lInstall the input shaft onto the front of the main shaft.
lInstall the input bearing retainer without shim onto the
front of the case.
lUsing a torque wrench, tighten the 4 bolts.
9. Install the 5th speed drive gear and blocking ring on the
counter shaft.
10. Install the 5th synchronizer and rail/fork.
11. Install the 5th synchronizer snap ring and oiling funnel.
12. Align the slots of the lever with the rollers of the reverse
fork and 5th shift rail. Apply sealer on the 5-R lever pivot
bolt and install it into the case.
Tightening Torque 28 Nm
13. Using a needle nose pliers, install the 5-R lever clip.

TRANSFER CASE (PART TIME 4408) 5D1-27
Adapter, Input Shaft and Carrier
72 Breather
73 Bolt
74 Adapter Assembly
75 Snap Ring
76 Oil Seal
77 Spiral Pin
78 Front Adapter
79 Retaining Ring
80 Bearing
81 Input Shaft Assembly 1. Place the planet carrier assembly on work bench to be the
retaining ring mounting groove upward.
2. Install the sun gear with the hub end up into the planet
carrier assembly and rotate the sun gear to make sure that
gears are fully engaged.
3. Align the tabs and install the thrust plate into the planet
carrier assembly.
4. Install the retaining ring to the planet carrier assembly.
5. Press the needle bearing into the input shaft and press the
new sleeve bearing into the input shaft assembly.
82 Sleeve Bearing
83 Needle Bearing
84 Input Shaft
85 Thrust Washer
86 Carrier Gear Assembly
87 Retaining Ring
88 Thrust Plate
89 Sun Gear
90 Planet Carrier Assembly
111 Case

5D2-6 TRANSFER CASE (TOD)
Input/Output diagram
TOD control unit and main wiring harness is linked by 30 pin
connector. Each pin joins with switche and actuator whose
details refer to the below diagram.
Battery Power
Ignition ON/OFF
Position Encoder 1
Position Encoder 2
Position Encoder 3
Position Encoder 4
4H / 4L Switch Signal
A/T “N” Position Signal
Speed / TPS Supply
Front Speed Sensor Input
Rear Speed Sensor Input
ABS Operation Signal
Brake Switch Signal
4
5
27
10
28
30
9
24
16
11
29
25
26
19
CAN H
CAN L
Shift Motor output port
(LO-HI)
Shift Motor output port
(HI-LO)
EMC
'4L' Indicator
Position Return
'4WD CHECK' IND
TPS/speed Sensor Ground
(Speed / TPS Return)
2
1
3
21
6
7
13 15
14
K-Line20 22
23
17
18

TRANSFER CASE (TOD) 5D2-7
1. K-LINE : Communication line for coding and diagnosis with SCANNER.
Classification of Pin No.
ClassificationPin No. Pin NameDescription
Power Supply17,18Ground
TOD control unit ground
4,19Battery
TOD control unit battery supply : (Fuse No 13,20A)
5IgnitionIgnition ON / OFF
27Position 1
Position encoder 1 : check of shift motor position
10Position 2
Position encoder 2 : check of shift motor position
28Position 3
Position encoder 3 : check of shift motor position
30Position 4
Position encoder 4 : check of shift motor position
94H/4L SwitchTransfer case mode input
24Auto T/M Neutral
Check of neutral gear position in Auto T/M
16Speed5V supply (TPS / speed sensor)
11Front Speed
Front speed sensor signal input Signal Input
29Rear Speed
Rear speed sensor signal input
25ABS Operation
ABS ON / OFF
6Position Return
Position encoder ground
13Speed / TPS ReturnGround for speed sensor / TPS
22CAN-LCAN bus low line
23CAN-HCAN bus high line
2,15Motor LO-HIMotor output port
- LO to HI : join with battery
- HI to LO (or motor brake) : join with ground
1,14Motor HI-LO
Motor output port
- HI to LO : join with battery
- LO to HI (or motor brake) : join with ground
3EMCTOD output
Signal Output
214L IlluminationIlluminates “4L” indicator
7Diagnosis Display
4WD check lamp illuminator
- Upon defect ; Ground circuit
20K-LINE1)Diagnosis

TRANSFER CASE (TOD) 5D2-11
4. Electric Shift Default Mode
If the motor fails to reach its destination, the TCCU will attempt the following (in order):
a. The TCCU will wait 3 seconds then attempt the shift again.
b. If the second attempt to reach the destination fails the TCCU will wait 3 seconds then attempt to rotate the
motor back to the original position. If successful, all future shifts will be inhibited until the Ignition is cycled.
c. If the attempt to return to the original position fails, the TCCU will wait 3 seconds then attempt to rotate the
motor to the original position again. If the second attempt to return to the original position is successful, the
“4WD CHECK” lamp will be illuminated, and all future shifts will be inhibited until the Ignition is cycled.
d. If the second attempt to return to the original position fails the motor will be turned off, the “4WD CHECK” lamp
will be illuminated, and all future shifts will be inhibited until the Ignition is cycled.
TODTM System Operation
The TODTM System is responsible for distributing torque between the front and rear axles. The TCCU monitors the
propshaft speeds, operating range (High/Low), and ABS activity and then applies a calculated amount of torque to
the front axle by Pulse Width Modulating the current applied to the EMC.
1. Touch-off Torque
The minimum EMC Duty Cycle is based on the vehicle speed and throttle position
The TCCU receives the TPS signal from the following sources:
On vehicles equipped with CAN, the TCCU receives the TPS signal from the CAN bus.
2. When Slip Detection
The TCCU continuously monitors the front and rear propshaft speeds to detect wheel slip.
3. Wheel Slip Control
When wheel slip is detected the TCCU controls the EMC duty cycle as necessary until the wheel slip is reduced
below the allowable limit. The EMC Duty Cycle will then be reduced to the Touch-Off value.
4. Brake/ABS Strategy
When the ABS System is active, the EMC Duty Cycle is set to a fixed duty cycle (30%) to aid in braking without
counteracting the ABS System.
5. 4L Strategy
When the system is operating in 4L, the TCCU continues TOD
TM (operation provided that the propshaft speed is
below 175 rpm (5220 pulses/minute)). When the speed increases above 175 rpm, the EMC Duty Cycle is set to
the maximum value (88%) which applies the maximum available torque to the front axle.