2003 SSANGYONG MUSSO oil

CLUTCH 5C-7
PEDAL AND MASTER CYLINDER
1 Clutch Pedal
2 Clutch Master Cylinder
3 Clutch Tube
4 Clutch Oil Chamber5 Clutch Tube
6 Clutch Hose
7 Clutch Release Cylinder

CLUTCH 5C-11
5. Unscrew the bolts and remove the clutch cover, pressure
plate and clutch disc. NoticeBe careful not to drop the pressure plate and clutch disc.Installation Notice
Tightening Torque 21 - 27 Nm
6. Installation should follow the removal procedure in the reverse order. Notice
Before installation, clean oil and grease on the flywheel surface.
Do not clean the clutch disc and release bearing insolvent.

5C-12 CLUTCH
Inspection Procedure
1. Clutch Cover Check the diaphragm spring tip for wear and height
unevenness.
Check the pressure plate surface for wear, crack and
discoloration.
Check the strap plate rivet for looseness and replace
the clutch cover if loosened.
Unevenness Limit 0.8 mm
2. Clutch Disc Check the facing for rivet looseness, excessive runout,
sticks, oil and grease.
Measure the rivet head depth. If out limit, replace the disc.
3. Clutch Release Bearing The release bearing is permanently lubricated and
requires no cleaning.
Check the bearing for sticks, damage, abnormal noise,
turning drag and wear.
4. Release Fork If there is abnormal wear in contact point with bearing,
replace the release fork.
Wear Limit 0.3 mm

CLUTCH 5C-13
MASTER CYLINDER
1 Snap Pin
2 Clevis Pin
3 Clevis
4 Lock Nut
5 Flange Nut ........................................... 30-40 Nm
6 Push Rod
7 Cylinder Body
8 Oil Pipe ................................................ 15-18 Nm 9 Clamp
10 Reservoir
11 Spring
12 Piston Assembly
13 Boot
14 Plate
15 Snap Ring
Notice Do not disassemble the No.12.

CLUTCH 5C-17
CLUTCH OIL CHAMBER
1 Clutch Master Cylinder
2 Hydraulic Tube
3 Bolt 4 Clutch Oil Chamber
5 Hydraulic Tube
6 Clutch Release Cylinder
Notice
Installation should follow the removal procedure in the reverse order.
When installing, perform the bleeding procedures from chamber cylinder and release cylinder.

Model
TypeGear Ratio Oil Manufacturer WeightPart-Time 4408 (E)
E.S.O.F. Type
1 : 1
2.48 : 1
ATF S-3, S-4 or DEXRON II, III
1.2 L
Check : Every 15,000 km
Replace : Every 50,000 km Borg Warner30 kg
SECTION 5D1
TRANSFER CASE (PART TIME 4408)
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
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 thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5D1-1
General Specifications . . . . . . . . . . . . . . . . . 5D1-1
Schematic and Routing Diagram . . . . . . . . 5D1-2 Part Time Transfer Case - 4408 . . . . . . . . . . 5D1-2
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5D1-3
Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . 5D1-4 System Description . . . . . . . . . . . . . . . . . . . . 5D1-4
Self-Diagnosis Test . . . . . . . . . . . . . . . . . . . . 5D1-8Diagnostic Diagram . . . . . . . . . . . . . . . . . . .
5D1-9
Maintenance and Repair . . . . . . . . . . . . . 5D1-10
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 5D1-10
Maintenance of Transfer Case Lubricant . . 5D1-10
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-11
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
Transfer Case Control Unit (TCCU) . . . . . . 5D1-36
High LowSpecification Capacity Lubrication
Application
Description

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

5D1-10 TRANSFER CASE (PART TIME 4408)
MAINTENANCE AND REPAIR ON-VEHICLE SERVICE MAINTENANCE OF TRANSFER CASE LUBRICANT Oil Level Check Clean the oil level plug and surrounding area.
Remove the oil level plug and check whether oil is drip out or not.
Tighten the oil level plug.
Oil Change Clean the oil level plug and surrounding area
Place a suitable container under the transfer case.
Remove the oil and tighten the drain plug.
Fill the oil through the oil level plug until oil begins todrip out.
Tighten the oil level plug.
Cautions for oil level check and plugs tightening Do not use an impact wrench to remove or tighten theoil level plug or drain plug since this will damage thethreads in the transfer case.
Tightening Torque 20 - 30 Nm