1998 SSANGYONG MUSSO service interval

GENERAL INFORMATION 0B-9
Chassis and Body
Months
MAINTENANCE
ITEMMAINTENANCE INTERVALKilometers or time in months, whichever comes first
120 105 90 75 60 45 30 15 1
96 84 72 60 48 36 24 12
- x1,000 km
Exhaust pipes & mountings
Brake/Clutch fluid(3)(4)
Parking brake/Brake pads F & R (5)
Brake line & connections (including booster)
Manual transmission oil (3)
Clutch & brake pedal free play
Front & Rear Differential Fluid (3)I
R
I
I
I
I
I-
-
-
I
I
-
II
I
I
I
I
I
II
R
I
I
I
I
II
I
I
I
R
I
RI
I
I
I
I
I
II
R
I
I
R
I
RI
I
I
I
I
I
II
R
I
I
I
I
I
Automatic transmission fluid (MB W4A040) (6)
Automatic transmission fluid (BTRA M74)
Chassis & underbody bolts & nuts tight/secure
Tire condition & inflation pressure
Wheel alignment (7)
Steering wheel & linkage
Power steering fluid & lines* (3)
Drive shaft boots
Seat belts, buckles & anchors
Lubricate locks, hinges & bonnet latchI
I
I
I
II
I
I
I
I
I
I
I
I
II
I
I
I
I
I
I
I
I
IR
I
I
I
I
I
I
I
II
I
I
I
I
I
I
I
II
I
I
I
I
I
I
I
I
IR
R
I
I
I
I
I
I
I
II
I
I
I
I
I
I
I
I
Transfer case fluidRIII
Inspect & ADJUST when abnormal condition is noted
I
I
I
I
I
I
I
I
I
Chart Symbols :
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
R - Replace or change.
(3) Refer to “Recommended fluids and lubricants”.
(4) Change the brake / clutch fluid every 15,000 km if the vehicle is mainly driven under severe conditions:
- Driving in hilly or mountainous terrain, or
- Towing a trailer frequently
(5) More frequent maintenance is required if under severe condition : short distance driving, extensive idling, frequent low -
speed operation in stop-and-go traffic or driving in dusty condition.
(6) Change automatic transaxle fluid and filter every 75,000 km if the vehicle is mainly driven under severe conditions.
- In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or
- In hilly or mountainous terrain, or
- When doing frequent trailer towing, or
- Uses such as found in taxi, police or delivery service.
(7) If necessary, rotate and balance wheels.

GENERAL INFORMATION 0B-11
Chassis and Body
Months
-
MAINTENANCE
ITEMMAINTENANCE INTERVAL
Kilometers or time in months, whichever comes first
100 90 80 70 60 50 40 30 20 10 1
60 54 48 42 36 30 24 18 12 6 x1,000 km
Exhaust pipes & mountings
Brake/clutch fluid(3) (4)
Parking brake/Brake pads (F & R) (5)
Brake line & connections (including booster)
Manual transmission fluid (3)
Clutch & brake pedal free play
F & R Differential fluid (3)
I
II
I
I
I
I
I
II
I
I
I
I
I
II
R
I
I
I
I
II
I
I
I
I
I
II
I
I
I
R
I
RI
R
I
I
I
I
II
I
I
I
I
I
II
I
I
I
I
I
II
R
I
I
I
I
II
I
I
I
R
I
R
Automatic transmission fluid (BTRA M74) (6)
Chassis & underbody bolts & nuts tight/secure
Tire condition & inflation pressure
Wheel alignment (7)
Steering wheel & linkage
Power steering fluid & lines* (3)
Drive shaft boots
Seat belts, buckles & anchors
Lubricate locks, hinges & bonnet latchI
I
I
I
I
I
I
II
I
I
I
I
I
I
II
I
I
I
I
I
I
I
II
I
I
I
I
I
I
II
I
I
I
I
I
I
II
I
I
I
I
I
I
II
I
I
I
I
I
II
I
I
I
I
I
I
II
I
I
I
I
I
I
I
Transfer case fluid (3)R
IR
I II
I
I
I
I
II
I
I
I
I
I
I
I
I
Inspect & ADJUST when abnormal condition is noted
II
I
Chart Symbols :
I - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
R - Replace or change.
(3) Refer to “Recommended fluids and lubricants”.
(4) Change the brake / clutch fluid more regularly if the vehicle is mainly driven under severe conditions :
- Driving in hilly or mountainous terrain, or
- Towing a trailer frequently
(5) More frequent maintenance is required if under severe condition : short distance driving, extensive idling, frequent low -
speed operation in stop-and-go traffic or driving in dusty condition.
(6) Change automatic transmission fluid every 70,000 km if the vehicle is mainly driven under severe conditions.
- In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or
- In hilly or mountainous terrain, or
- When doing frequent trailer towing, or
- Uses such as found in taxi, police or delivery service.
(7) If necessary, rotate and balance wheels.

ANTILOCK BRAKE SYSTEM 4F-9
SELF DIAGNOSIS
ABS, ABS/ABD 5.3
Initialization
1. Turn the ignition switch to "ON" position.
2. Using a service connector, ground the No.13 terminal of
diagnosis socket and No.1 ground terminal for 3 - 4 seconds.
Notice
If it is over 5 seconds, initialization will not be performed.
3. After completing the initialization, ABS warning lamp will be
turned on until the ignition switch is turned to "OFF" position.
Output of Fault Code
1. Normal : 1 pulse (normal code 01)
2. Abnormal : 1 pulse (fault code)
Notice
lIf appeared initial fault code and above 2 differnt fault
code, perform again initialization.
lFault code will be output the numbers of fault code with
a interval of 1 second.(turn on : 0.75 sec., turn off : 0.25
sec.)
Fault Code Elimination
After repairing the defect parts, eliminate the fault from ECU.
1. Ground the diagnosis No.13 terminal to No.1 ground terminal
for over 5 seconds.
2. Turn the igniotion switch to "OFF" position.
Notice
lIf not eliminate the fault code, the code will be maintained.
lCheck and find the other defect parts with performing
the imitialization again, if the fault code will be output,
repair the defect parts completely.

Model
Type
Gear Ratio
Oil
Weight (Dry)
SECTION 5B
MANUAL TRANSMISSION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5B-1
General Specifications . . . . . . . . . . . . . . . . . . 5B-1
Fastener Tightening Specifications . . . . . . . . . 5B-2
External View . . . . . . . . . . . . . . . . . . . . . . . . 5B-3
Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-3
Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5
Will not Shift (Control Lever Moves) . . . . . . . . 5B-5
Hard Shift or Control Lever Will not Move Into
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5
Gears Crash When Shifting . . . . . . . . . . . . . . 5B-5
Transmission Jumps Out . . . . . . . . . . . . . . . . . 5B-6
Transmission Locked in One Gear . . . . . . . . . 5B-6
Transmission Noise . . . . . . . . . . . . . . . . . . . . . 5B-6
Transmission Leakage . . . . . . . . . . . . . . . . . . 5B-7Diagnosis Table . . . . . . . . . . . . . . . . . . . . . . . 5B-8
Component Locator . . . . . . . . . . . . . . . . . . . 5B-9
Maintenance and Repair . . . . . . . . . . . . . . 5B-11
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 5B-11
Shift Control Cable . . . . . . . . . . . . . . . . . . . . 5B-11
Transmission . . . . . . . . . . . . . . . . . . . . . . . . 5B-14
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17
Major Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17
Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-27
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-32
Counter Shaft . . . . . . . . . . . . . . . . . . . . . . . . 5B-34
Extension Housing . . . . . . . . . . . . . . . . . . . . 5B-35
Shift Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-36
Inspection of Components . . . . . . . . . . . . . . 5B-40
Pre-Installation Checks . . . . . . . . . . . . . . . . . 5B-45
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Description
T5WC
Floor Change
3.97 : 1
2.34 : 1
1.46 : 1
1.00 : 1
0.85 :1
3.71 : 1
ATF DEXRON II / III
3.4 L
Check : Every 15,000km, Replace : Every 50,000km
33kg 1st
2nd
3rd
4th
5th
Reverse
Specification
Capacity(litre)
Change Interval
Notice
Add LUBRIZOL (280cc) in oil after overhauling.

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

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

SECTION 8B
SUPPLEMENTAL RESTRAINT SYSTEM(SRS)
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 8B-1
General Specifications . . . . . . . . . . . . . . . . . . 8B-1
Schematic and Routing Diagrams . . . . . . . . 8B-2
Air Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2
Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-3
Function Description . . . . . . . . . . . . . . . . . . 8B-4
Air Bag Module . . . . . . . . . . . . . . . . . . . . . . . . 8B-6
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-7
Self Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 8B-10
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . 8B-16
TABLE OF CONTENTS
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
GENERAL SPECIFICATIONS
Application
Air bag System Deployment Time
Detection Time
Operating Temperature
Storage Temperature
Air Bag Replacement Interval
Voltage Range
Current Consumption
Acceleration Range
Max. Acceleration
Voltage Ramp
Energy Reservation
Inflator Ignition Energy
Squib Resistance
Air Bag Warning Lamp ON Time (When Ignition ON)Description
< 20ms
< 5ms
-40°C ~ +85°C
-40°C ~ +90°C
Every 10-year after installation
9-16V
5ms after ignition switch ON < 1A,
5ms ~ 5sec. <300mA, after 5sec. < 100mA
+/-50g
+/-600g pulse
0.5 ~ 2.0 V/s
150ms after battery disconnection
4.3mJ
2.15 ± 0.35 W
6 sec.
Air Bag Diagram . . . . . . . . . . . . . . . . . . . . . . 8B-17
Maintenance and Repair . . . . . . . . . . . . . . 8B-18
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 8B-18
Air Bag Module . . . . . . . . . . . . . . . . . . . . . . . 8B-18
Clock Spring . . . . . . . . . . . . . . . . . . . . . . . . . 8B-19
Air Bag Control Unit (AC4) . . . . . . . . . . . . . . 8B-21
General Description and System
Operation . . . . . . . . . . . . . . . . . . . . . . . . 8B-22
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-22
Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-22

SUPPLEMENTAL RESTRAINT SYSTEM(SRS) 8B-3
CAUTIONS
Failure to follow the correct service procedure can cause air bag damage or personal injury due to unexpected air
bag deployment. Before service (removal and installation of part, check for replacement), please be weal noticed of
following items for your correct service.
1. For service, turn the ignition switch to ‘LOCK’ position and wait for 30 seconds after disconnecting the negative
battery cable.
2. If the vehicle collapsed, remove the air bag ECU first to reserve the crash records.
3, Never use other vehicles’ air bag components and replace with specified new part.
4. Never disassemble or repair the air bag module, air bag unit and wiring harness to re-use.
5. Replace the air bag module and air bag unit with new if it dropped, cracked or damaged.
6. Only qualified technicians in service shop should check or repair the air bag,
7. Before service, should be well noticed of warning labels on the vehicle.
A. Sun Visor Side
[Warning]
Pull down the sun visor and see SRS air bag
warning lamp on the head lining.
B. Head Lining
[Warning]
1 . This vehicle is equipped with air bag. Air bag is
supplemental device for the seatbelt. Fasten
your seatbelt.
2. This air bag should be replaced by authorized
supplier within replacement intervals.
3. When the ignition key is turned to ON position,
SRS warning lamp will turn on for 6 sec. and go
off. In this case, the system is normal.
For the following cases, see service manual.
- SRS warning lamp does not turn on.
- SRS warning lamp does not go off.
- SRS warning lamp continues to blink.
C. Steering Wheel Body Inner
[Warning]
Before removing the steering wheel, read service
manual first. Set the front wheels straight forward
and align the center position marks of SRS clock
spring. Improper removal or installation of the
steering wheel can damage the SRS components.D. Engine Compartment
[Warning]
This vehicle is equipped with air bag. Before
checking the engine compartment, read service
manual first. Faultuy check and service can cause
SRS air bag deployment and system defects that
can be led to severe damage.
E. Battery Cable
[Warning]
Before disconnecting the battery power, read
service manual first.