SsangYong Rexton. Manual - part 591

SSANGYONG Y200

5D2-12 TRANSFER CASE - TOD

1 Case
2 Bearing
3 Ring Gear
4 Oil Seal
5 Retaining Ring
6 Input Shaft
7 Carrier
8 Pinion Gear
9 Pinion Shaft

10 Thrust Washer
11 Needle Roller
12 Spacer
13 Bearing
14 Bushing
15 Sun Gear
16 Thrust Plate
17 Hub
18 Bearing
19 Snap Ring
20 Snap Ring
21 Snap Ring
22 Hub Reduction
23 Shift Fork
24 Spacer
25 Shaft Shift
26 Spring
27 Cam
28 Breather Hose
29 Breather Plug
30 Shift Rail
31 Intermediate Shaft
32 Thrust Washer
33 Pump
34 Clamp Hose
35 Upper Sprocket
36 Thrust Washer

37 Chain
38 Cover
39 Bearing
40 Oil Seal
41 Dowel Pin
42 Bearing Sleeve
43 Seal
44 Snap Ring
45 Center Bearing Support
46 Ball Bearing
47 Dowel Pin
48 Viscous Coupling
49 Pinion Gear
50 Thrust Washer
51 Pinion Shaft
52 Thrust Washer
53 Thrust Washer
54 Bushing
55 Output Shaft
56 Ring Gear
57 Retaining Ring
58 Needle Bearing
59 Ball Bearing
60 Speed Gear
61 Flange
62 Oil Seal
63 Washer
64 Nut
65 Flange
66 Dust Deflector
67 Tone Wheel
68 Bolt
69 Motor
70 Bolt
71 Cap Screw

TRANSFER CASE - TOD 5D2-13

SSANGYONG Y200

TRANSFER CASE ASSEMBLY

YAD5D050

1 Input Shaft
2 Air Control Cap
3 Front Companion Flange
4 Rear Companion Flange

5 Drain Plug
6 Filler Plug
7 Shift Cam Driving Motor

SSANGYONG Y200

5D2-14 TRANSFER CASE - TOD

FUNCTION DESCRIPTION

TOD system controls clutch mechanism to comply with
rotation in front and rear propeller shaft and if its
d i f f e r e n c e e x c e e d s t h e p e r m i s s i b l e r a n g e ,
corresponding power is distributed into front wheel
through EMC (Electro-Magnetic Clutch). Hall effect
sensor signals speed on front and rear propeller shafts
going through with TOD control unit.

Transfer case clutch coil is activated by variable current
on exceeding difference of speed in front and rear
propeller shafts.

Select 4L Mode

When select 4L mode, EMC is locked to apply
maximum torque into front and rear propeller shafts.
Shift motor rotates also 4L position by rotation of cam
thus propeller shaft torque changes from 1 : 1 to 2.48 : 1
by planetary gear set.

Deselect 4L Mode

When select 4H mode, the 4WD mode is deselected
and returns the 4WD - high speed mode.

•

“4H” switch : Slef-return Type

•

“4L” switch : Push Lock Type

YAD5D060

TOD SYSTEM SELECT MODE

4H is the mode when drive normally of which gear ratio
is 1 : 1 and 4L mode distributes power to front and
rear wheels 50 : 50 of which gear ratio is 2.48 : 1.

COMPONENT FUNCTION

Shift Motor

It locates backside transfer case, which drives rotary
helical cam. When mode select switch changes to 4L,
shift fork is on position for 2.48:1 by rotation of helical
cam.

Transfer Case

TOD transfer case distributes power into front and rear
axle by operation of 4H/4L switch and shift motor.
Shifting 4H to 4L, is performed towards reducing HI-
LO collar by means for connection HI-LO shift fork with
output shaft in order to join with planetary gear. Torque
transmits input shaft then sun gear rotating front
planetary gear. Front planetary gear join with output
shaft and drives LO position.

TOD Control Unit

TOD control unit is located on the floor under the driver
seat.

YAD5D070

Shape and function of TOD Control Unit

YAD5D080

TRANSFER CASE - TOD 5D2-15

SSANGYONG Y200

Speed Sensor, Clutch Coil, Motor Connector

Speed Sensor, Clutch Coil and Motor Connector are
located at the upper & rear side of the transfer case
(upper shift motor) as shown.

•

Shift Motor Connector : Black (upper arrow as
shown)

•

Speed Sensor and Clutch Coil Connector : White
(lower arrow as shown)

Shift Motor Connector

YAD5D090

YAD5D100

Speed sensor, clutch coil connector

YAD5D110

Function

Clutch Coil

Front Speed Return

Front Speed

Front Speed Sensor Voltage Supply

Rear Speed Sensor Voltage Supply

Rear Speed

Rear Speed Return

Pin

Function

Motor HI-LO (clockwise)

Motor HI-LO (counter-clockwise)

Position Return

Position 1

Position 2

Position 3

Position 4

Pin

Function

Motor HI-LO

Motor LO-HI

EMC

Battery (+)

Ignition

Position Return

Diagnosis Display

HI / LO Switch

Position 2

Front Speed

TPS Supply (Diesel)

Speed/TPS Return

Motor HI-LO

Motor LO-HI

Pin

Function

Speed Reference

Ground

Battery (+)

K-LINE

4L Illumination

CAN-H

CAN-L

Auto T/M, Neutral

ABS Input

Brake Switch

Position 1

Position 3

Rear Speed

Position 4

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