2003 SSANGYONG MUSSO 4wd

TRANSFER CASE (PART TIME 4408) 5D1-3
Cannot Front Wheel Drive when Shifted 4H,4LDIAGNOSIS
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 Chain Action
Check sliding parts, replace if necessary.
Noise in 4WD Operation
Checks
Improper or low oil Loosened bolts or mounted partsNoisy T/C bearing Noisy gears Action
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 Pressure Action
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 CaseLeakage from Other PartsBreather CloggingImproper or too much OilLoosened Sealing Bolts Improperly Applied Sealant Worn or Damaged Oil Seal

5D1-4 TRANSFER CASE (PART TIME 4408)SELF-DIAGNOSIS
SYSTEM DESCRIPTION
1. TCCU detects transfer case system malfunctions and indicates malfunctioning part(s) through flashing 4H,4L indicator lights.
Using a service connector, connect it to the diagnosis box in the engine room and read the flashing of the ‘4WD
CHECK ’ indicator light.
The flashing indicator light will show you defective code(s).
2. Identify 7 defective codes after reading the flashing indicator light.
TCCU
Shift motor
Magnetic synchronizer clutch
Speed sensor
Hub solenoid
Selector switch
Motor position sensor
3. Transfer case system is malfunctioning when: 4H ,4L indicator lights are remain on after 0.6 second when turning the ignition switch ‘ON ’
4H,4L indicator lights are continuously come on during driving.
4. If only 1 part is malfunctioning, ‘4WD CHECK ’ indicator light
will display defective code 3 times continuously.
5. If more then 2 part is malfunctioning, the first malfunctioning part will be displayed 3 times and following malfunctioningparts will be displayed .
6. To read defective code, connect the service connector and turn the ignition switch 'ON'.
7. After repairing, eliminate the defective code stored in the TCCU. NoticeBefore replacing the malfunction parts with defective code, check the wires and connectors for proper condition.

TRANSFER CASE (PART TIME 4408) 5D1-5
Defective Code Reading
1. Position the ignition switch to ‘OFF ’
2. Using a service connector, connect the No.2 pin ( lgnition ) and No.6 pin (TCCU) of the diagnosis socket in the engine room.
3. Position the ignition switch to 'ON'.
4. Read the flashing ‘4WD CHECK ’ indicator light and identify
the malfunctioning part.
How to Eliminate the Falut Code
1. Position the ignition switch to ‘OFF ’
2. Using a service connector, connect the No.2 pin (GND) and No.6 pin (TCCU) of the diagnosis socket in the engine room.
3. Position the ignition switch to ‘ON ’ over 5 seconds.
4. Do defective code reading and make sure that all defective codes are eliminated.

5D1-6 TRANSFER CASE (PART TIME 4408)
Diagnostic Table
Connect a service connector. If turn the ignition switch ‘ON ’
‘ 4WD CHECK ’ indicator light will come on for 0.6 second and
turn off for 3 seconds and then display a defective code 3
times continuously.
No. Defective Code
Malfunctioning Part
1
2 3 4
5 TCCU
Shift Motor
Synchronizer Clutch
Speed SensorHub Solenoid
4WD CHECK Light ON OFF
Defective Code
4WD CHECK Light ON OFF
Defective Code
4WD CHECKLight ONOFF
Defective Code
4WD CHECKLight ONOFF
Defective Code
4WD CHECK Light ONOFF
Defective Code

TRANSFER CASE (PART TIME 4408) 5D1-7
No.Defective Code
Malfunctioning Part
6
7
Selector Switch
Motor Positon Sensor
4WD CHECKLight ONOFF
Defective Code
4WD CHECK Light ON OFF
Defective Code

5D1-18 TRANSFER CASE (PART TIME 4408)

1. Remove the retaining ring and clutch housing from the shiftcollar hub.
2. Remove the shift collar hub from the output shaft.
3. Separate the 2WD - 4WD lock-up assembly and lock-up fork from the output shaft and remove the rail shaft.
4. To remove the 2WD - 4WD lock-up assembly, separate the return spring, lock-up hub and snap ring from the lock-up
collar.
30 Retaining Ring
31 Clutch Housing
32 Shift Collar Housing
33 2WD/4WD Lock-up Assembly
34 Snap Ring
35 Lock-up Hub
36 Return Spring
37 Lock-up Collar
38 Rail Shaft
39 Lock-up Fork
55 Output Shaft
40 Snap Ring
41 Spacer
42 Drive Sprocket
43 Driven Sprocket
44 Drive Chain
55 Output Shaft(Rear)
71 Output Shaft(Front)

1. Remove the snap ring and spacer from the output shaft.
2. Remove the drive chain, driven sprocket and drive sprocket
from the output shaft.
3. Separate the chain and sprocket when removing the assembly.

1. Remove the 4 bolts and retainer and separate the output
shaft and rear pump cover.
2. Loosen the hose clamp and remove the hose coupling from the pump housing.
3. Remove the hose clamp, hose coupling and strainer.
4. Remove 2 pump pins and spring from the output shaft.
5. Separate the front pump and remove the output shaft.
45 Shaft and Pump Assembly
46 Bolt
47 Pump Retainer
48 Rear Pump Cover
49 Hose Clamp
50 Hose Coupling
51 Pump Housing
52 Pump Pin
53 Spring
54 Front Pump Cover
55 Output Shaft
56 Strainer

TRANSFER CASE (PART TIME 4408) 5D1-31
Lockup Shift
1. Install the lockup hub and return spring to the lockup collarand insert the snap ring.
2. Install the rail shaft through reduction shift fork assembly previously installed and into the blind hole in case.
3. Engage the lockup fork into the 2WD/4WD groove and check operation.
4. Install the shift collar hub to the output shaft spline.
5. Install the previously assembled electric shift cam and assemble the clutch housing as follows.
Rotate the shift cam assembly to right so that the end of
the torsion spring contacts with reduction shift fork side.
Holding the rail shaft, lift up the fork assembly slightly. Adjust electric shift cam assembly so that the roller on
reduction shift fork assembly is in groove in shift cam and button on lockup fork is on cam end.
Install the clutch housing over shift collar hub and insert
the retaining ring into the clutch collar hub groove. 30 Retaining Ring
31 Clutch Housing
32 Shift Collar Housing
33 2WD/4WD
Lockup Assembly
34 Snap Ring
38 Rail Shaft
39 Lockup Fork
59 Reduction Shift Fork Assembly
100 Electric Shift Cam
101 Torsion Spring 35 Lockup Hub
36 Return Spring
37 Lockup Collar
38 Rail Shaft
39 Lockup Fork
55 Output Shaft

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.