SsangYong Rexton. Manual - part 582

PART TIME - T/C  5D1-19

SSANGYONG  Y200

1 Transfer Case
2 Spring Washer
3 Oil Seal
4 Companion Flange
5 Shift shaft
6 Oil Seal
7 Pipe Plug
8 Screw
9 Bolt

10 Speed Sensor and Harness Bracket
11 Speed Sensor Assembly
12 Speed Sensor
13 O-Ring
14 Locking Clip
15 Connector
16 Motor Assembly
17 Oil Seal
18 Bearing
19 Bolt
20 Pump Assembly
21 Output Shaft Assembly
22 Bearing
23 Ring Gear
24 Cover Assembly
25 Nut
26 Snap Ring
27 Bearing
28 Needle Bearing
30 Clutch Coil Assembly
31 Speed Gear
32 Oil Seal
33 Return Spring
34 Magnet
35 Clutch Housing
36 Snap Ring
37 Snap Ring
38 Lock-up Hub
39 Sleeve Return Spring
40 Lock-up Collar

41 Rail Shaft
42 Lock-up Fork
43 Snap ring
44 Spacer
45 Driven Sprocket
46 Driving Sprocket
47 Drive Chain
48 Nut
49 Gasket
53 Spring Pin
54 Hose Clamp
55 Hose Coupling
56 Oil Strainer
58 Reduction Hub
59 Shift Fork Assembly
60 Shift Fork Facing
61 Roller and Retainer
66 Nut
67 Plane Washer
68 Oil Seal
71 Spacer
72 Front Output Assembly
73 Breather
74 Bolt
75 Front Adapter Assembly
76 Snap Ring
80 Snap Ring
81 Bearing
82 Input Shaft Assembly
83 Sleeve Assembly
84 Needle Bearing
86 Thrust Washer
87 Retaining Ring
88 Thrust Plate
89 Sun Gear
90 Gear Carrier Assembly
97 Electric Shift Cam
99 Spacer

SSANGYONG  Y200

5D1-20  PART TIME - T/C

;;;;;;

YAD5D220

ON-VEHICLE SERVICE

MAINTENANCE OF TRANSFER
CASE LUBRICANT

1. 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.

Installation Notice

YAD5D230

MAINTENANCE AND REPAIR

Tightening Torque

20 - 30 N•m

 (15 - 22 lb-ft)

2. 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 to drip out.

•

Tighten the oil level plug.

3. Cautions for oil level check and plugs tightening

•

Do not use an impact wrench to remove or
tighten the oil level plug or drain plug since this
will damage the threads in the transfer case.

PART TIME - T/C  5D1-21

SSANGYONG  Y200

YAD5D240

4H AND 4L INDICATOR

When the ignition switch turns on, 4H and 4L indicators
turn on for 0.6 seconds and turn off.

Notice: If 4H and 4L indicators do not turn on, check
the related bulb, the wiring harness and TCCU.

J1 - 7

J1 - 8

J1 - 13

J1 - 14

J1 - 15

J1 - 16

J1 - 17

J1 - 23

4H or 4L

2H

4H indicator light ON

4H indicator light OFF

2H or 4H

4L

Clutch pedal applied

Clutch pedal released

4L indicator light ON

4L indicator light OFF

Motor OFF

Motor ON

Motor OFF

Motor ON

Auto locking hub ON

Auto locking hub OFF

TCCU INSPECTION

4.75 - 5.35

0 - 0.50

< 1.00

> 11.00

4.75 - 5.35

0 - 0.50

< 0.50

> 11.00

< 1.00

> 11.00

< 1.00

> 11.00

< 1.00

> 11.00

> 11.00

< 1.00

Pin No.

Voltage(V)

Operation Condition

Notice:

•

DC 12V for the TCCU operation should be
maintained.

•

In case of J1-8 and J1-15, indicator light will turn
on for 0.6 second when turn the ignition switch ON.

•

If 4H and 4L indicator lights remain turned on when
turn the ignition switch on or during driving, perform
the TCCU diagnosis.

SSANGYONG  Y200

5D1-22  PART TIME - T/C

YAD5D300

7. Support the transfer case with jack and remove

the front and rear propeller shafts from the transfer
case.

Installation Notice

81 - 89 N•m

(60 - 66 lb-ft)

70 - 90 N•m

(52 - 66 lb-ft)

Tightening

Torque

Front

Rear

YAD5D270

YAD5D280

TRANSFER CASE ASSEMBLY

1. Disconnect the negative terminal from the battery.

2. Lift up the vehicle and fix it safely.

3. Remove the damper mounting bolt.

4. Remove the drain plug and drain the oil.

Reinstall the drain plug.

Installation Notice

Tightening Torque

19 - 30 N•m

 (14 - 22 lb-ft)

YAD5D290

5. Remove the breather hose.

6. Disconnect the speedometer cable connector and

other cable connectors and wiring harnesses.