2003 SSANGYONG MUSSO check oil

5D1-22 TRANSFER CASE (PART TIME 4408) Cleaning Procedure Notice Before cleaning, check the magnet for thepresence of metal particles which indicate internalchipping of the transfer case.
1. Using cleaning solvent, clean the residual oil and dirtdeposits.Notice
During cleaning, be careful not to damage the metal surfaces.
2. After cleaning, dry the parts with low pressure (Max. 20 psi) compressed air.
3. Lubricate the ball bearings and needle bearings with transfer case oil after cleaning. NoticeProtect the lubricated bearings from dust.
Inspection Procedure
1. Visually check the all removed parts. Notice
Always replace the hose coupling, O-ring and oil seal with new parts.
2. Inspection Terms Burr : Local rise of material forming protruding sharp
edge
Chip : An area from which a small fragment has been
broken off or cut
Crack : Surface break of line nature indicating partial or
complete separation of material.
Excessive wear : Heavy or obvious wear beyond
expectations considering conditions of operation.
Indentation : Displacement of material caused by localized
heavy contact.
Galling : Breakdown of metal surface due to excessive
friction between parts. Particles of the softer materialare torn loose and welded to the harder material.
Nick : Local break or notch, usually displacement of
material rather than loss.
Scoring : Tear or break in metal surface from contact
under abnormal pressure.
Step wear : Heavy wear that produces a step that can
be seen or felt between adjacent contact and noncontactsurfaces.
Uneven wear : Condition of localized, unevenly distributed
wear Includes hollows, shiny spots, uneven polish and other visual indications.

TRANSFER CASE (TOD) 5D2-25
Error in electro - magnetic clutch : fault code “1721 ”, “1722 ”
Phenomenon
1. Upon diagnosis by SCAN-100, it displays on fault
codes “1721,1722 ”.
Cause
1. Defect in electro - magnetic clutch
2. Defect in connector or wiring
- Open or short from EMC to the supply : 1721
- Short EMC to ground : 1722
Ye sNo
C1
Ye sNo
Ye s
No
11-15Vdc Ye s
No
C2
Ye sNo
Test Stage / ContentsResult
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check relevant connector connection status.
1. Check relevant connector connection status with TOD
control unit.
- Does it connect correctly ?
2. Check connection status of speed sensor and clutch coil connector (7 pin) in transfer case.
- Does it connect correctly ?
3. In case of bad connection, connect it correctly then perform the follows :
a. Delete the memorized fault code in control unit withScan - 100.
b. Ignition “OFF ”.
c. Ignition “ON ”.
d. Diagnose by SCAN-100
- Does it display on fault codes “1721,1722 ” ?
Check supply voltage into electro-magnetic clutch.
1. Ignition “ON ”
2. Measure voltage between pin 4/19(+) and 17/18(-) in TOD control unit connector.
- Specified value
- Measured value is within specified range ?
3. If the specified value would not be measured, perform the follows :
a. Check battery voltage (charging condition)
b. Check open circuit on No.13 fuse (20A)
c. Check relevant wires.
- Is the above 3a, 3b, 3c normal ? Perform C1-2 stage Perform C1-3 stage Perform C2 stage Normal system
Perform C2 stage Perform C1-3 stage Perform C3 stage Perform C2-3 stage Perform C3 stage

Charging/ Replace battery
Replace fuse
Repair wires

TRANSFER CASE (TOD) 5D2-27
Defect in speed sensor : fault code 1731, 1732, 1733, 1734, 1735,1736
Phenomenon
1. Upon diagnosis by SCANNER, it displays on fault code
1731, 1732, 1733, 1734, 1735 and 1736.
2. “4WD CHECK ” lamp illuminates continuously when
ignition “ON ”.
Cause
1. Defect of speed sensor (front, rear).
2. Defect of power supply.
4.75-5.25Vdc
Ye sNo
D1
Ye s
No
D2
Ye s
Ye s
Ye sNo
D3 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check power supply of speed sensor.
1. Ignition
“ON ” or driving mode
2. Measure supply voltage between pin 16 (+) and 13 (-) in
TOD control unit connector using digital multi-tester.
- Specified value
- Measured value is within specified range ?
Check connection status of connector.
1. Check connection status of speed sensor/clutch coil connector and TOD control unit connector.
- Does it connect correctly ?
2. In case of bad connection, connect it correctly then perform the follows:
a. Delete the memorized fault code in control unit by
SCANNER.
b. Ignition “OFF ”.
c. Ignition “ON ”.
d. Diagnose by SCANNER.
- It does not display fault code.- It displays one or more fault code among 1731 to1736.
Check output wave of front and rear speed sensor.
1. Upon driving mode.
2. Check output wave of each speed sensor by SCANNER.
3. Is it normal on output wave ? Perform D3 stage Perform D2 stage
Perform D3 stagePerform D2-2 stage Normal system Perform D3 stage Perform D4 stage Replace speed sensor then perform D2-2 stage

5D2-40 TRANSFER CASE (TOD)
REPLACEMENT OF OIL Oil Specification Specified Oil Level
SpecificationStandard
Capacity Service A.T.F S-3, S-4 or Dexron II, III
1.4 Litre
Inspection every 15,000km, Replacement every 50,000km =
Oil Replacement
1. Lift on vehicle then make sure on safety.
2. Prepare a vessel to drain transfer case oil.
3. Release filler plug.
4. Drain oil completely.
5. Wash drain plug and than tighten. Installation Notice
Tightening Torque 19 - 30 Nm
6. Replenish standardized oil by specified level through filler plug hole.
7. Tighten filler plug after washing.
Installation Notice
8. Check oil leakage.
Tightening Torque 19 - 30 Nm
. .

5D2-48 TRANSFER CASE (TOD)
6. Install the front planet to the sun gear and input shaft.Install the internal snap ring to the planetary carrier.
7. Place the tanged snap ring in the case. Expand snap ring with snap ring pliers and install planetary carrier assembly. Check installation by holding the case and carefully tappingthe face of the input shaft against a wooden block to makesure the snap ring is installed.
8. Remove all traces of gasket sealant from the front case and mounting adapter mating surfaces. Install a bead ofgasket sealant on the surface of the front case.
9. Install the high-low shift fork and high-low collar as an assembly into the front planet. Notice Make sure that the nylon wear pads are installed on the shift fork and snapped securely into place.
12 Rear Output Shaft
13 Oil Strainer
14 Coupling Hose
15 Hose Clamp
16 Pump Body
10. If new pump is used, align the flat of the output shaft and
the flat of the pump. Slide the pump onto the output shaft.
Do not disassemble oil pump. It is serviced only as an
assembly. Check the pump to make sure the pump
rotates freely.
Do not remove the plastic insert from the bore of the
new pump. Discard it after it slides out during pumpinstallation to the rear output shaft.
While turning the output shaft, prime the pump through
the oil filter pickup tube or housing inlet hole with clean
Automatic Transmission Fluid or equivalent.
11. Inspect the outside surfaces and bore of the oil pump. If there is no discoloration in the pump housing, gear or cover,and the pump bore and the lube holes of the output shaft show evidence of oil, the pump is working.

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 AngleOuter Steering Angle
TypeMaximum 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 BoltReturn Pipe Nut Slotted Nut Steering Gearbox Bolt
N m
30 - 40 12 - 1812 - 1835 - 45 35 - 45

6A-2 POWER STEERING SYSTEMChecks
Damaged or Binding Steering Ball Joint Improper Preload of Steering Pinion
Damaged Wheel or TireFaulty Suspension System Checks
Worn Steering Gear Worn or Damaged Steering Ball Joint Loosened Steering Gearbox Bolts Checks
Damaged Steering Linkage
Damaged Wheel and Tire Faulty Brake System Faulty Suspension System Checks
Lack of Lubrication Abnormal Wear or Binding of Steering Ball Joint Damaged or Faulty Steering GearImproper Preload of Steering PinionFaulty Steering Shaft JointSteering Fluid Leaks Lack of Fluid or Air-in System Faulty Steering Oil PumpDamaged or Loosened Pump Drive BeltClogging 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 LinterferenceLoosened Steering LinkageDamaged or Loosened Oil Pump Drive BeltLoosened Oil Pump Bracket Loosened Oil Pump Mounting Bolt Air-in SystemFaulty Oil Pump Checks
Damaged Steering LinkageLoosened Steering Gearbox Mounting Bolt Damaged or Binding Steering Ball Joint Worn or Damaged Front Wheel Bearing
Damaged Wheel or TireFaulty Suspension System STEERING WHEEL SHIMMY
Action
Replace
Retighten
Replace Replace
Repair or replaceRepair or replace
ABNORMAL NOISE FROM STEERING SYSTEM
Action
Retighten
Replace gear assembly Replace
Retighten
Adjust or replace Retighten RetightenBleed
Replace