2003 SSANGYONG MUSSO battery

Type Clutch Pedal Clutch Disc Clutch Master Cylinder Clutch Release Cylinder Clutch FluidDescription
Hydraulic
Suspended 158 mm
5 - 10 mm
Single Dry Diaphragm
9.85 - 10.2 mm 9.2 mm
19.8 mm
15.87 mm
14.0 mm
17.46 mm
SAE J1703 / DOT3
SECTION 5C
CLUTCH
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 General Specifications . . . . . . . . . . . . . . . . . . 5C-1
Fastener Tightening Specifications . . . . . . . . . 5C-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5C-3 Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5C-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Clutch Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4
Poor Disengagement . . . . . . . . . . . . . . . . . . . 5C-4
Hard to Shift or Will not Shift . . . . . . . . . . . . . . 5C-4
Clutch Chatters When Starting . . . . . . . . . . . . 5C-4
Difficult Pedal Operation . . . . . . . . . . . . . . . . . 5C-5
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.
Application
Type Max. Pedal StrokePedal Free Play
TypeThickness of Disc Stroke Inner DiameterStrokeInner DiameterFree
With Load
Clutch Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5
Component Locator . . . . . . . . . . . . . . . . . . . 5C-6 Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . 5C-6
Pedal and Master Cylinder . . . . . . . . . . . . . . . 5C-7
Maintenance and Repair . . . . . . . . . . . . . . . 5C-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 5C-8
Bleeding of Clutch System . . . . . . . . . . . . . . . 5C-8
Clutch Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 5C-13
Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15
Clutch Oil Chamber . . . . . . . . . . . . . . . . . . . 5C-17

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

5D1-12 TRANSFER CASE (PART TIME 4408)
Removal & Installation Procedure
1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the drain plug and drain the oil.Reinstall the drain plug.
* If planar damper is installed, unscrew 4 bolts and remove the planar damper.
Installation Notice
Tightening Torque 19 - 30 Nm
4. Remove the breather hose.
5. Disconnect the speedometer cable connector and other cable connectors and wiring harnesses.
6. Support the transfer case with jack and remove the front and rear propeller shafts from the transfer case. Installation Notice
Front
Rear 81 - 89 Nm 70 - 80 NmTightening Torque

5D2-6 TRANSFER CASE (TOD) Input/Output diagram TOD control unit and main wiring harness is linked by 30 pin
connector. Each pin joins with switche and actuator whosedetails refer to the below diagram.
Battery Power
Ignition ON/OFF
Position Encoder 1
Position Encoder 2
Position Encoder 3
Position Encoder 4
4H / 4L Switch Signal
A/T “N” Position Signal
Speed / TPS Supply
Front Speed Sensor Input
Rear Speed Sensor Input
ABS Operation Signal
Brake Switch Signal
4 5271028309241611292526
19 CAN H
CAN L
Shift Motor output port (LO-HI)
Shift Motor output port (HI-LO)
EMC
'4L' Indicator
Position Return
'4WD CHECK' IND
TPS/speed Sensor Ground (Speed / TPS Return)
2 13216713
1514
K-Line
20
22
23
17 18

TRANSFER CASE (TOD) 5D2-7
1. K-LINE : Communication line for coding and diagnosis with SCANNER.
Classification of Pin No.
Classification
Pin No. Pin Name Description
Power Supply 17,18
Ground
TOD control unit ground
4,19 Battery TOD control unit battery supply : (Fuse No 13,20A)
5 Ignition Ignition ON / OFF
27 Position 1
Position encoder 1 : check of shift motor position
10 Position 2 Position encoder 2 : check of shift motor position
28 Position 3
Position encoder 3 : check of shift motor position
30 Position 4
Position encoder 4 : check of shift motor position
9 4H/4L Switch Transfer case mode input
24 Auto T/M Neutral Check of neutral gear position in Auto T/M 16 Speed 5V supply (TPS / speed sensor)
11 Front Speed
Front speed sensor signal input
Signal Input
29 Rear Speed Rear speed sensor signal input
25 ABS Operation
ABS ON / OFF
6 Position Return
Position encoder ground
13 Speed / TPS Return Ground for speed sensor / TPS
2 2 CAN-L CAN bus low line
23 CAN-H
CAN bus high line
2,15 Motor LO-HI Motor output port
- LO to HI : join with battery
- HI to LO (or motor brake) : join with ground
1,14 Motor HI-LO Motor output port
- HI to LO : join with battery
- LO to HI (or motor brake) : join with ground
3 EMC TOD output
Signal Output
21 4L Illumination Illuminates
“4L ” indicator
7 Diagnosis Display
4WD check lamp illuminator
- Upon defect ; Ground circuit
20K-LINE1)
Diagnosis

5D2-12 TRANSFER CASE (TOD)Pin1 2345 6 78
Function
Motor HI-LO Motor LO-HI EMC
Battery (+)
Ignition
Position Return
Diagnosis Display - Pin
9
10 11
1213 14 1516 Function
HI / LO Switch Position 2
Front Speed
TPS Supply (Diesel) Speed/TPS Return
Motor HI-LOMotor LO-HI
Speed Reference Pin
1718192021 22 2324 Function
GroundGround
Battery (+) K-LINE
4L Illumination
CAN-HCAN-L
Auto T/M, Neutral Pin
2526272829 30 - - Function ABS Input
Brake Switch
Position 1 Position 3
Rear Speed
Position 4 --
TOD CONTROL UNIT
Shape and function of TOD Control Unit

TRANSFER CASE (TOD) 5D2-17
ClassificationTCCU
EMC
Speed Sensor
Shift Motor
Position Encoder
DIAGNOSTIC TROUBLE CODES (DTC
’s)
1. Diagnostic Trouble Code Retention The first time a fault is detected a DTC is stored in the TCCU ’s
Non-Volatile memory. This DTC will remain in memory until the TCCU is instructed to erase DTC ’s by SCAN-100. DTC ’s
will not be erased by disconnecting power to the TCCU.
2. Diagnostic Trouble Code AssignmentsCode 1714 171517161721 1722 1731173217331734 1735 173617411742 1743 1750175117521753 1754 Description
EEPROM Checksum Fault TPS Loss of Signal
TPS Out of Range
EMC Open / Short to Battery
EMC Short to ground
Front Speed Sensor Voltage Low
Front Speed Sensor Voltage High
Rear Speed Sensor Voltage Low
Rear Speed Sensor Voltage High
Speed Sensor Reference Voltage Low
Speed Sensor Reference Voltage High Motor Open / Shorted to Battery
Motor Output Shorted to Ground
Shift System Timeout
General Position Encoder Fault (Invalid Code) Position 1 Shorted to Ground Position 2 Shorted to GroundPosition 3 Shorted to Ground Position 4 Shorted to Ground

TRANSFER CASE (TOD) 5D2-21
DIAGNOSIS Malfunction interior TOD control unit ; fault code 1714
Phenomenon
1. When ignition “ON ”, “4WD CHECK ” lamp illuminates
continuously.
2. On diagnosis by SCAN-100, it displays fault code “1714 ”.
Cause ; Error of EEPROM checksum in TOD control unit
Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check power supply for TOD control unit. 1. Disconnect 30 pin connector from TOD control unit.
2. Ignition “ON ”.
3. Using multi-tester, measure voltage between pin 5(+)
and 17/18 (-). - Specified value - Measured value is within specified range ? 11-14 Vdc
Ye sNo Perform A2 stagePerform A3 stage
Check connection status in TOD control unit connector.
1. Check connection status.
- Is it connected exactly?
2. In case of mal-connection, connect tightly then perform the follows.
a. Delete fault code using Scan-100.
b. Ignition “OFF ”.
c. Ignition “ON ”.
d. Diagnose by Scan-100.
- Does it display fault code “1714 ”? Ye s
No
Ye s No
Check short of 10A fuse (fuse No.20).
1. Detach No.20 fuse from engine room fuse box.
2. Check the existence of short.
- Is fuse normal? Yes
No
Check ground of TOD control unit.
1. Ignition “ON ”.
2. Check voltage between 4/19 (+) pin and 17/18 (-)
using multi-tester (keep connection status).
- Specified value (battery is good)
- Measured value
3. Check short between 17/18 pin and body after disconnect 30 pin connector.
- Is resistance " "? 12Vdc (battery
voltage)
Ye s
No
Ye sNo
A1 A2 A3 A4
Perform A3 stage Perform A2 stage Perform A3 stage Normal system Perform A4 stage Replace fuse, then perform A1 stage Perform A4-3 stage Replace TOD controlunit Repair ground wiring Ground is O.K., perform A5 stage