SsangYong Rexton. Service manual - part 577

SSANGYONG  Y200

5C-16  CLUTCH

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CLUTCH PEDAL

1. Pedal Stroke (A).

Notice: To adjust the pedal stroke, loosen the lock
nut (H) of the interlock switch (G) and turn the two
lock auto until the stroke is correct.

2. Pedal Height (B).

Notice: To adjust the pedal height, loosen the lock
nut (C) of the stopper bolt(D) and turn the stopper
bolt until the height is correct.

3. Pedal Free Play (E).

Notice: To adjust the pedal free play, loosen the
lock nut (F) of the master cylinder and turn the
push rod until the free play is correct.

4. Check the fulcrum pin and the bushing for wear,

the pedal for bending and the spring for damage.

YAD5C310

Max. Stroke

158 mm

148 mm

GSL

DSL

Height (From the Floor

Carpet)

182 ± 5 mm

Free Play

5 - 10 N•m

YAD5C300

4. Concentric Slave Cylinder

•

Check any heat damage, abnormal noise, poor
rotation and wear of the concentric slave
cylinder bearing.

CLUTCH  5C-17

SSANGYONG  Y200

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

602 589 00 40 00

Engine Lock

661 589 00 15 00

Centering Pin

YAD5C320

YAD5C330

SECTION 5D1

PART TIME - T/C

TABLE OF CONTENTS

General Infromation and Operation .................. 5D1-2

4WD Operation Overview ................................... 5D1-2

System Structure ............................................... 5D1-3

2H Mode (Rear Wheel Drive) .............................. 5D1-5

4H Mode (4WD Drive - High Speed) ................... 5D1-6

4H Mode (4WD Drive - Low Speed) .................... 5D1-7

System Description ........................................... 5D1-8

Specifications .................................................... 5D1-9

Diagnostic Infromation and Procedures .......... 5D1-10

General Diagnosis ........................................... 5D1-10

Self-Diagnosis Test .......................................... 5D1-11

Diagnostic Diagram ......................................... 5D1-15

Component Locator ......................................... 5D1-16

Cross Sectional View ....................................... 5D1-16

Transfer Case Assembly .................................. 5D1-17

Disassembly and Assembly ............................ 5D1-18

Maintenance and Repair ................................. 5D1-20

On-Vehicle Service ............................................. 5D1-20

Maintenance of Transfer Case Lubricant ........... 5D1-20

4H and 4L Indicator ......................................... 5D1-21

TCCU Inspection ............................................. 5D1-21

Transfer Case Assembly .................................. 5D1-22

TCCU .............................................................. 5D1-24

Unit Repair ........................................................ 5D1-25

Disassembly Procedure ................................... 5D1-25

Assembly Procedure ....................................... 5D1-35

SSANGYONG  Y200

5D1-2  PART TIME - T/C

2WD Drive(Rear

Wheel Drive)

4WD Drive(High

Speed)

4WD Drive(Low

Speed)

2WD Drive 

↔

 4WD

Drive(High Speed)

2WD Drive, 4WD

Drive(High Speed)

↔

 4WD Drive(Low

Speed)

GENERAL INFORMATION AND OPERATION

4WD OPERATION OVERVIEW

Driving Type

Transferring

2H

4H

4L

2H 

↔

 4H

2H, 4H 

↔

 4L

Application

•

Normal Driving on the normal road or highway, or

high speed driving

•

Slipped road such as snow, rainy, sand, mud etc.

•

Max driving force requiring condition such as

towing, rough road.

•

When a vehicle is driven in turning at low speed on

the paved road, a vibration and a noise may be

occurred by tight corner braking.

•

2WD 

↔

 4WD transfer is possible below 70 km

without operating the clutch.

•

Manual Transmission

Transfer starts after the vehicle stops and the clutch

is applied

•

Automatic Transmission

Transfer starts after the vehicle stops and the shift

lever is shifted [N] position.

Notice: After the vehicle stops and the mode switch
is selected with applying the brake pedal, shifting
[N-R-N] makes the mode transfer easier.

Operation Condition

Mode Position