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SsangYong Rexton. Service manual - part 605

SSANGYONG Y200

5D2-68 TRANSFER CASE - TOD

03E-019

YAD5D210

YAD5D220

YAD5D230

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. D i s c o n n e c t t r a n s m i s s i o n e x t e n s i o n w i r i n g

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.

TRANSFER CASE - TOD 5D2-69

SSANGYONG Y200

03E-019

YAD5D240

YAD5D250

YAD5D260

YAD5D270

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.

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

extension housing in transmission.

Installation Notice

12. Unscrew 4 units of M12 bolts from case flange

then disconnect rear propeller shaft from transfer
case.

Installation Notice

11. Unscrew 4 units of M12 bolts from case flange

then disconnect front propeller shaft from transfer
case.

Installation Notice

Tightening Torque

81 - 89 N•m

(60 - 66 lb-ft)

Tightening Torque

81 - 89 N•m

(60 - 66 lb-ft)

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.

Tightening Torque

35 - 60 N•m

(26 - 44 lb-ft)

SSANGYONG Y200

5D2-70 TRANSFER CASE - TOD

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YAD5D280

YAD5D290

YAD5D300

TOD CONTROL UNIT

Removal & Installation Procedure

1. Disconnect (-) cable from battery.

2. Pull toward the driver seat and disconnect the 30

pin connector from TOD control unit.

YAD5D310

4. Installation should follow the removal procedure

in the reverse order.

Notice: When replace TOD control unit, it is
required to make a coding correspondent with
vehicle specification.

Installation Notice

3. Unscrew 2 bolts.

Tightening Torque

10 N•m (89 lb-in)

SHIFT MOTOR

Removal & Installation Procedure

1. Disconnect (-) cable from battery.

2. Disconnect shift motor/magnetic clutch coil

connector (black pin7) upper backside.

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

4. Unscrew a bracket mounting bolt (M10).

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

TRANSFER CASE - TOD 5D2-71

SSANGYONG Y200

03E-019

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.

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

YAD5D320

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.

YAD5D330

6. Unscrew rear speed sensor mounting bolt (M10)

from upper side of rear case flange.

Content .. 603 604 605 606 ..