SsangYong Korando II (1996-2006 year). Manual - part 347

SSANGYONG MY2002

5D1-16  TRANSFER CASE

KAA5D040

NO 4WD LOW INDICATOR STAYS ON WITH IGNITION SWITCH ON

Circuit Description

When the ignition switch turns to ON the transfer case
control unit (TCCU) illuminates 4WD CHECK and 4WD
LOWindicator to check bulb operation and turns off
after 0.6 seconds. Then TCCU starts self-diagnosis
and illuminate 4WD CHECK indicator when TCCU
detects any fault.

Diagnostic Aids

•

If the 4WD LOW indicator illuminates steadily the
transfer case in 4 wheel drive low range and 4H/4L
switch set to 4L. It is normal condition.

•

The 4WD LOW indicator also illuminates steadily if
the terminal B9 of TCCU connector is shorted to
ground. The shorted wire or terminals should be re-
paired.

Test Description

The number(s) below refer to step(s) on the diagnostic
table.

2. This step checks for the normal bulb operation.

Step

1

2

Action

Yes

Go to Step 2

System OK

No

Go to Step 3

-

Value(s)

Check the position of 4H/4L switch.
Does the 4H/4L switch set on 4L.
1. Turn the ignition switch to ON.
2. Set the shift lever to N (neutral).
3. Turn the 4H/4L switch to 4H.
Does the 4WD LOWindicator go off?

TRANSFER CASE  5D1-17

SSANGYONG MY2002

Step

3

4

5

6

7

Action

Yes

Go to Step 4

System OK

Go to Step 6

System OK

System OK

No

Go to Step 5

-

System OK

Go to Step-7

-

Value(s)

1. Turn the ignition switch to ON.
2. Set the shift lever to N (neutral).
3. Turn the 4H/4L switch to 4L.
Does the 4WD LOWindicator go off?
The wiring of 4H/4L switch is reversed. Repair the
wiring.
Is the repair complete?
1. Turn the ignition OFF.
2. Check the pin or terminals for damage or improper

connection.

3. Reconnect all the connectors.
4. Turn the ignition ON.
Does the 4WD LOW indicator come on steadily?
Repair any short to ground circuit between terminal B9
of TCCU connector and terminal A8 of cluster.
Is the repair complete?
Replace the TCCU.
Is the repair complete?

SSANGYONG MY2002

5D1-66  TRANSFER CASE

KAA5D240

KAA5D250

ON-VEHICLE SERVICE

OIL REPLACEMENT

Important: Use only recommended oil or not the trans-
fer case will be severely damaged. Inspect every
10,000 km and replace every 60,000 km.

Specified Oil Level

The oil level should be just under the filler hole.

REPAIR INSTRUCTIONS

Oil Replacement

1. Lift the vehicle and make sure safety.

2. Prepare a vessel to drain transfer case oil.

3. Remove the planner damper, if equipped.

4. Remove the drain plug and filler plug, and drain

the oil completely.

5. Install and tighten the drain plug.

Installation Notice

6. Replenish recommended transfer case oil to speci-

fied oil level through the filler plughole.

7. Install and tighten the filler plug.

Installation Notice

8. Check oil leakage.

9. Install the planner damper.

Installation Notice

Tightening Torque

19 - 30 N•m

 (14 - 22  lb-ft)

Tightening Torque

4 - 6 N•m

 (35 - 53  lb-in)

Tightening Torque

29 - 41 N•m

 (21 - 30  lb-ft)

TRANSFER CASE  5D1-67

SSANGYONG MY2002

KAA5D260

KAA5D270

TRANSFER CASE CONTROL UNIT
(TCCU)

Removal and Installation Procedure

1. Turn the ignition switch to OFF.

2. Disconnect two connectors from the TCCU under

the driver seat.

3. Remove two bolts and the TCCU.

Installation Notice

Tightening Torque

10  N•m (7 lb-ft)

•

When replacing the TCCU, it is required to a
c o d - i n g  c o r r e s p o n d e n t   w i t h   t h e   v e h i c l e
specification. Refer to “TCCU Coding” in this
section.

4. Installation should follow the removal procedure

in the reverse order.

TRANSFER CASE

Removal and Installation Procedure

1. Disconnect the negative battery cable.

2. Lift the vehicle and make sure safety.

Notice:  Be careful not to touch the catalytic
converter which is very hot after driving or engine
running.

3. Remove the drain plug and drain the transfer case

oil. Refer to “Oil Replacement” in this section.

Installation Notice

4. Disconnect the transmission extension wiring con-

nector on backside of transfer case.

5. Disconnect shift motor and clutch coil connector

(black 7 pin) on upper backside of transfer case.

6. Disconnect front and rear speed sensor connector

(white 7 pin).

7. Disconnect speedometer sensor connector.

Tightening Torque

19 - 30 N•m

 (14 - 22  lb-ft)