2003 SSANGYONG MUSSO transmission

CLUTCH 5C-9
CLUTCH DISC Preceding Work : Removal of the transmission
1 Clutch Disc
2 Clutch Cover Assembly
3 Release Bearing
4 Clutch Housing
Tools 602 589 00 40 00 Engine Lock661 589 00 15 00 Centering Pin 5 Washer
6 Bolt
........................................................... 23 Nm
7 Washer
8 Bolt ........................................................... 44 Nm

TRANSFER CASE (PART TIME 4408) 5D1-11
TRANSFER CASE
1 Rear Companion Flange
2 Cover
3 Front Companion Flange
4 Breather Plug
5 Case
6 Input Shaft
7 Mounting Bolt ..................................... 38-52 Nm8 Transmission Adapter
9 Bolt .....................................................
81-59 Nm
10 Washer 11 Front Propeller Shaft
12 Bolt ..................................................... 81-89 Nm
13 Washer
14 Rear Propeller Shaft

TRANSFER CASE (PART TIME 4408) 5D1-13
7. Remove the center mounting nuts and end sides mountingbolts of the cross member and then remove the cross
member. Installation Notice
Tightening Torque(1)
Tightening Torque(2) 21 - 35 Nm62 - 93 Nm
8. Remove the transfer case by removing the bolts attaching
the transfer case to the transmission. Installation Notice Notice Apply long-term grease to the inner spline of the transfer case input shaft.
9. Installation should follow the removal procedure in the reverse order.
Tightening Torque 38 - 51 Nm

5D1-36 TRANSFER CASE (PART TIME 4408)
TRANSFER CASE CONTROL UNIT (TCCU) System Description TCCU is located under the front left handed seat and permits the vehicle to shift from two-wheel drive to four-wheel drive
(and back shift) according to driver ’s switch operation during
driving (For the shifting between 4WD HIGH and 4WD LOW, stop the vehicle).
1. Shifting from 2H to 4H
Position the transfer case switch from '2H' to '4H'.
Shifting is possible during driving.
'4WD Hl' indicator light will turn on.
2. Shifting from 4H to 2H Position the transfer case switch from '4H' to '2H'.
Shifting is possible during driving.
'4WD Hl' indicator light will turn off.
3. Shifting between 4H and 4L Shifting is possible when the vehicle is almost stopped
(below approx. 2 km/h), so it would be better stop the vehicle.
In case of manual transmission equipped vehicle, apply
clutch pedal.
In case of auto transmission equipped vehicle, put the
lever position into 'N'.
Position the transfer case switch '4H' to '4L' or '4L' to
'4H'.
According to the shifted position, indicator light will turn
on.
Notice
If there are malfunctions during shifting,'4H' or '4L' indicator light will blink.

TRANSFER CASE (TOD) 5D2-5
Definitions
Rear Speed Sensor A Hall Effect speed sensor which produces a square wave. 0-5Vdc signal inresponse 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 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 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 TM
Torque 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 Range The highest (numerically lowest = 1 :1) gear ratio between the input and outputsof the Transfer Case.
Low Range The 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 theposition 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 indicatesthat the transmission is in neutral.
Shift Inhibit Speed The vehicle speed above which Transfer Case shifts are disallowed. Vehicle speedis indicated by propshaft speed measurement.

5D2-10 TRANSFER CASE (TOD) Electric Shift System Operation
The Electric Shift System is responsible for changing the Transfer Case gear ratio by controlling the electric shift
motor. The TCCU monitors the 4H/4L switch, neutral switch, speed sensors, position encoder, and ignition switch. A range change is initiated when
1. The 4H/4L Switch is changed from 4H to 4L or from 4L to 4H.
2. The motor position (as indicated by the position encoder) does not match the 4H/4L Switch immediately after theignition is turned on.
1. Shift Criteria When a range change is initiated a Diagnostic Test will be completed on the motor, speed sensors, and position
encoder. If the Diagnostic Test fails, the shift will not be attempted. If all components are operating properly, theTCCU will attempt a range change after the following shift criteria are met:
a. The transmission is in neutral for 2 seconds after the shift is requested.
b. Both propshaft speeds are below 87 rpm (2580 pulses/minute).
If the transmission is taken out of neutral before 2 seconds has elapsed, or either propshaft speed increases above the limit, the shift will be suspended and the 4L Indicator will continue to blink until the criteria are met again or the 4H/4L Switch is returned to the original position.
2. Range Change When the shift criteria are met, the motor is rotated in the appropriate direction (as determined by the selectorswitch) until one of the following occurs:
a. The motor reaches its destination.
b. The motor is on for 5 seconds without reaching its destination. The shift has failed and the TCCU will respond as default mode.
c. A fault occurs with either the motor or position encoder. Refer to the diagnosis requirement.
When the motor is energized, the Ignition, 4H/4L Switch, propshaft speeds, and transmission neutral inputs are ignored.
3. Indicator Function Once a range change has been initiated the 4L Indicator will begin to blink at a rate of 0.3 seconds on, 0.3 seconds off until the shift is completed or canceled.
If a successful shift has been completed, the 4L Indicator will be illuminated if the motor is in Low and it will be turned off if the motor is in High. 4L Indicator illuminates as below figure.
 4H
4L
@ : shift is completed
 4L
4H
@ : shift is completed

TRANSFER CASE (TOD) 5D2-19
ClassificationEngine Type
Transmission/Vehicle Type Axle Ratio
Tire Size
Coding Required
1. Replacement of TOD control unit.
2. Adjustment by input error.
3. Change of tire specification.
Items
Gasoline Engine (E32) 661 Diesel Engine
661LA Diesel Turbo Engine
662 Diesel Engine
662LA Diesel Turbo Engine Manual Transmission
Automatic Transmission MUSSO
KORANDO 3.734.554.895.38 5.86
P215 P235P255P275
Coding Method
1. Check and record engine type, axle ratio and tire size.
2. Ignition “OFF ”.
3. Connect SCANNER with diagnosis connector in engine room.
4. Ignition “ON ”.
5. Read the current memorized specification in TOD control unit.
6. Compare memorized specification with the checked record. If not matched, perform a coding.
7. Read again memorized coding specification in TOD control unit for confirmation of coding.
8. Check coding specification whether it matches with vehicle or not. If not, perform a coding again.
Coding items

5D2-34 TRANSFER CASE (TOD) TRANSFER CASE (TOD)
1 Transmission
2 TOD Transfer Case
3 Extension Housing
4 Bolt....................................................... 35-60Nm5 Front Propeller Shaft
6 Bolt
....................................................... 81-89Nm
7 Rear Propeller Shaft
8 Bolt ....................................................... 81-89Nm