SsangYong Musso. Manual - part 522

TRANSFER CASE (TOD)  5D2-35

Removal & Installation Procedure

1. Disconnect (-) cable from battery.

2. Lift on vehicle and make sure on safety.

Notice

Be careful for catalytic converter due to high temperature
after driving or engine running.

3. Prepare a vessel to drain transfer case and manual

transmission oil.

4. Release drain plug and drain transfer case and manual

transmission oil.

If planar damper is installed, unscrew 4 bolts and remove
the planar damper.

Notice

Oil drain should be along with whole transfer case
disassembly and assembly.

5. Disconnect transmission extension wiring connector back

side transfer case.

Notice

When disconnect connector, make sure on direction of
locking tab towards inside.

6. Disconnect shift motor/clutch coil connect (Black 7 pin)

connector upper backside.

7. Disconnect front and rear speed sensor connector (white

7 pin).

8. Disconnect speedometer sensor connector right upper

side.

9. Disconnect breather tube front upper side transfer case

(upper connecting point of transfer case and front
propeller).

10. Prepare hydraulic jack and support transfer case assembly.

5D2-36  TRANSFER CASE (TOD)

11. Unscrew 4 units of M12 bolts from case flange then

disconnect front propeller shaft from transfer case.

Installation Notice

Tightening  Torque

81 - 89 Nm

12. Unscrew 4 units of M12 bolts from case flange then

disconnect rear propeller shaft from transfer case.

Installation Notice

13. Unscrew 5 units of mounting bolt (M12)  from extension

housing in transmission.

Installation Notice

Tightening  Torque

81 - 89 Nm

Tightening  Torque

35 - 60 Nm

Notice

Make sure the connecting surface is clean.

Applying long-life grease spline inside transfer case input
shaft.

14. Installation should follow the removal procedure in the

reverse order.

TRANSFER CASE (TOD)  5D2-37

Replacement of Shift Motor

1. Disconnect (-) cable from battery.

2. Disconnect shift motor/clutch coil connector (black pin7)

upper backside.

3. Unscrew 3 units of shift motor mounting bolts (M10).

4. Unscrew 1unit of bracket mounting bolt (M10).

Installation Notice

Tightening Torque

9 - 11 Nm

Notice

When disconnecting shift motor and mounting bracket, it is
required to unscrew 2 units of adjusting bolts (M10) form
motor and bracket.

5. Keep shift motor even then pull rearward.

6. Clean connection surface of transfer case and shift motor.

7. If necessary, make a test by SCANNER with shift motor

assembly.

Notice

Do not disassemble shift motor. If necessary, replace by
shift motor assembly unit.

8. Applying sealant into connecting surface for new shift motor.

9. Installation should follow the removal procedure in the

reverse order. Before installation, make sure that motor
position match with mode of 4H/4L switch.

Reference

When accord position of motor with 4H/4L switch and transfer
case match position of the disconnected motor and new
one.

5D2-38  TRANSFER CASE (TOD)

SPEED SENSOR IN FRONT AND
REAR PROPELLER SHAFT

Replacement Procedure

1. Disconnect (-) cable from battery.

2. Detach shift motor assembly.

3. Disconnect front and rear speed sensor connector (white 3

pin) upper backside transfer case.

4. Disconnect speed sensor connect from locking sleeve by

pushing.

5. Disconnect wire stick cap from the detached connector.

6. Unscrew rear speed sensor mounting bolt (M10) from upper

side of rear case flange.

7. Detach sensor from transfer case by lifting up using tool.

Notice

When disconnect sensor, make sure on adequate pressure
due to sensitiveness with shock.

8. Disconnect taping from both protection tube ends that wrap

3 wires of speed sensor and 1 wire of clutch coil.

9. Disconnect tube.