SsangYong Rexton. Service manual — part 605
SSANGYONG Y200
5D2-68 TRANSFER CASE - TOD
03E-019
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
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.
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