SsangYong Musso. Manual - part 508

5D1-16  TRANSFER CASE (PART TIME 4408)

Disassembly Procedure

<Companion Flange>

1. Holding the companion flange, remove the nut and washer

and then remove the companion flange and oil seal.

2. Remove the 2 plugs from the cover.

1 Nut
2 Washer
3 Oil Seal
4 Companion Flange
5 Plug

25 Cover

6 Bolt
7 Washer
8 Bolt
9 Sensor and Harness Bracket

10 Sensor Assembly

11 Speed Sensor

12 O-ring
13 Motor Assembly
25 Cover

<Extension Electric Shift>

1. Remove the bolt, washer,3 bolts and harness bracket.

2. Remove the sensor assembly and remove the O-ring from

the speed sensor.

3. Remove the motor assembly.

TRANSFER CASE (PART TIME 4408)  5D1-17

1. Remove the 9 bolts, wiring harness clip and

identification tag.

Notice

Identification tag has information required for ordering
replacement parts, so be careful not to lose it.

2. Using a ‘-‘  driver, pry and disconnect the sealant

bond of the cover and required case.

3. Remove the oil seal, bearing, 3 nuts and clutch coil

assembly of the electric shift unit.

<Cover Assembly>

14 Bolt
15 Wiring Clip
16 Identification Tag
17 Cover Assembly
18 Oil Seal
19 Bearing
20 Nut
21 Clutch Coil Assembly
22 Snap Ring
23 Ball Bearing

4. Remove the snap ring and pull out the ball bearing

from the cover to remove the speed gear.

5. Pull out the needle bearing from the cover.

6. Pull out the oil seal from the slot in cover.

7. Remove the magnet form the slot in case.

8. Remove the return spring from the rail shaft.

9. Be careful not to damage the metal surface when

removing the sealant of the cover and case.

24 Needle Bearing
25 Cover
26 Magnet
27 Speed Gear
28 Oil Seal
29 Return Spring
38 Rail Shaft
55 Output Shaft

111 Transfer Case

5D1-18  TRANSFER CASE (PART TIME 4408)

<Lock-up Shift Parts>

1. Remove the retaining ring and clutch housing from the shift

collar hub.

2. Remove the shift collar hub from the output shaft.

3. Separate the 2WD - 4WD lock-up assembly and lock-up

fork from the output shaft and remove the rail shaft.

4. To remove the 2WD - 4WD lock-up assembly, separate the

return spring, lock-up hub and snap ring from the lock-up
collar.

30

Retaining Ring

31

Clutch Housing

32

Shift Collar Housing

33

2WD/4WD Lock-up Assembly

34

Snap Ring

35

Lock-up Hub

36

Return Spring

37

Lock-up Collar

38

Rail Shaft

39

Lock-up Fork

55

Output Shaft

40

Snap Ring

41

Spacer

42

Drive Sprocket

43

Driven Sprocket

44

Drive Chain

55

Output Shaft(Rear)

71

Output Shaft(Front)

<Drive Chains>

1. Remove the snap ring and spacer from the output shaft.

2. Remove the drive chain, driven sprocket and drive sprocket

from the output shaft.

3. Separate the chain and sprocket when removing the

assembly.

<Pump Parts>

1. Remove the 4 bolts and retainer and separate the output

shaft and rear pump cover.

2. Loosen the hose clamp and remove the hose coupling from

the pump housing.

3. Remove the hose clamp, hose coupling and strainer.

4. Remove 2 pump pins and spring from the output shaft.

5. Separate the front pump and remove the output shaft.

45

Shaft and Pump Assembly

46

Bolt

47

Pump Retainer

48

Rear Pump Cover

49

Hose Clamp

50

Hose Coupling

51

Pump Housing

52

Pump Pin

53

Spring

54

Front Pump Cover

55

Output Shaft

56

Strainer

TRANSFER CASE (PART TIME 4408)  5D1-19

<Front Output Assembly>

1. Holding the companion flange, remove the nut and washer

and then remove the companion flange and oil seal.

2. Remove the output shaft.

65 Nut
66 Washer
67 Oil Seal
70 Companion Flange
71 Output Shaft (front)

111 Case

57

Reduction Hub

58

Shift Fork Facing

59

Reduction Shift Fork Assembly

60

Roller Pin and Retainer Assembly

61

Retainer

62

Pin

63

Roller Cam

64

Reduction Shift Fork

<Reduction Shift Parts>

1. Remove the reduction hub and reduction shift fork assembly

from the case.

2. Remove the 2 shill fork facings from the shift fork assembly.

3. To remove the roller cam and pin, cut elf the plastic retainer

when disassembling the fork assembly.