SsangYong Stavic / SsangYong Rodius (2005 year). Service manual - part 361

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

51

TOD

STAVIC - 2004.09

4D

48. Install the bolts retaining the case halves and tighten.

Installation Notice

49. Install shift shaft oil seal if it is not installed.

50. Using pliers equipped with soft jaws, rotate the triangular

shaft so it is aligned with the triangular slot in the transfer
case shift motor.

Tightening torque

25 - 37 Nm

 (8 - 27 lb-in)

 [Notice]

If triangular shaft will not rotate, rotate the rear output shaft.

46. Coat the mating surface of the front case with a bead of

Black Non-Acid Cure Silicone Rubber or equivalent.

47. The following procedure must be followed prior to installing

the rear case onto the front case half:

• Align the output shaft with the rear case output shaft

bore.

• Align the helical cam with the rear case motor bore.

• If difficulty is encountered with seating the rear case,

tap the rear output shaft with a sharp blow using a
rubber mallet in a direction away from the triangular
shaft while pushing down on the rear case.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

52

TOD

STAVIC - 2004.09

4D

51. Tighten manually the two nuts that attach the slotted

support bracket to the end of the motor house.

52. Apply Black Non-Acid Cure Silicone Rubber or equivalent

to motor housing base and install on transfer case.

53. Install the transfer case shift motor and three bolts along

with speed sensor wire harness bracket and tighten.

Installation Notice

Tightening torque

8 - 11 Nm

 (71 - 97 lb-in)

54. Holding the slotted support bracket tight against the motor

housing end, secure the bracket to the transfer case,
tightening the bolt with lock washer.

Installation Notice

55. Retighten the two nuts that attach the slotted support

bracket to the end of the motor.

Installation Notice

56. Install the clutch coil wire terminal(brown) and other shift

motor wires to the 7-pin connector(black).

57. Install the connector retainer at the connector end.

58. Connect the front and rear speed sensors wiring to the

7-pin connector(white).

59. Install the rear case flange on the output shaft.

60. Install the rubber seal, output shaft yoke washer and nut.

Tighten the nut.

Installation Notice

61. Install the drain plug and tighten.

62. Fill the transfer case with 1.4 liters of Automatic

Transmission Fluid or equivalent.

63. Install the fill plug and tighten.

Installation Notice

64. Install the transfer case as outlined in removal and

Installation.

Tightening torque

8 - 11 Nm

 (71 - 97 lb-in)

Tightening torque

3 - 6 Nm

 (27 - 53 lb-in)

Tightening torque

137 - 196 Nm

Tightening torque

19 - 30 Nm

 (14 - 22 lb-in)

Tightening torque

19 - 30 Nm

 (14 - 22 lb-in)

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

53

TOD

STAVIC - 2004.09

4D

Name and Part Number

Application

661 589 01 37 00 (W 99 31 001 1B)

Pliers

Removal/installation of carrier
assembly in transfer case

DW 220 - 080 (W 99 31 005 0B)

Oil seal installer

Installation of oil seal to
transmission case

SPECIAL TOOLS AND EQUIPMENT

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

54

TOD

STAVIC - 2004.09

4D

TCCU periodically monitors the input and output while the system is in operation. When a fault is detected, the trouble
code is stored into TCCU memory.

If the ignition switch is turned to “OFF”, TCCU stops monitoring for input and output, however, when the ignition switch
is turned to “OFF” before shifting completes, TCCU continues monitoring for input and output required for the shifting.

1. SELF DIAGNOSIS TEST

Shift Motor Test

When TOD control unit detects a fault in shift motor or position encoder for over 1 second, “4WD CHECK” warning lamp
comes on and the trouble code is stored into memory.

• Shift motor fault occurs when the motor is in “OFF” state:

- short to ground in motor HI-LO circuit
- short to ground in motor LO-HI circuit
- open in motor circuit

• Shift motor fault occurs when the motor is in normal operation state:

- short to ground in motor HI-LO circuit
- short to ground in motor LO-HI circuit
- short between motor LO-HI and motor HI-LO circuit
- open in motor circuit

• Position encoder fault occur when

- Detected unmatched code with 9 valid position codes
- An encoder circuit is short to ground

• When the fault occurs before the shift operation is started, the TOD control unit does not respond to any shift

command.

• When, after receiving shift command, the fault occurs without any operation, the TOD control unit cancels the

command and does not respond to any following shift command.

• If TOD control unit, even while shift command is in progress, detects an invalid position code, it stops the operation

and turns motor to “HIGH” position. After then, TOD control unit does not respond to any shift command.

• When the shift motor and position encoder assembly fault (fault other than motor fault that is caused when normal

power supply is applied) is restored continuously for 1 second, the TOD control unit function becomes normal. At
this time, “4WD CHECK” warning lamp comes on but the trouble code is stored into memory.

• The trouble code being detected in shift motor during its operation is defined as timeout.

• The trouble code for shift motor can be erased by using scanner.

Position Encoder Test

• When the system detects a fault in shift motor for over 1 second, “4WD CHECK” warning lamp comes on and the

trouble code is stored into memory.

• Position encoder fault can be divided into general encoder fault and short to ground of position encoder circuit.

- General encoder fault: Invalid position code input
- Short to ground of position encoder circuit: Ground for encoder circuit

TROUBLE DIAGNOSIS