SsangYong Musso. Manual - part 511

5D1-28  TRANSFER CASE (PART TIME 4408)

6. Install the planet carrier assembly onto the input shaft

and install the thrust washer. Press the bearing over

input shaft.

7. After pressing the bearing, install the retaining ring.

8. Press the pin into the front adapter.

9. Slowly press the oil seal into the front adapter.

10. Install the front adapter assembly.

Notice

After installation, make sure that snap ring is correctly
installed into the groove.

11. Position the input shaft assembly over front cover and

engage into the bearing groove by expanding the ends of
snap ring.

12. Apply 1.6mm bead of sealant on the mounting face for

the transfer case and tighten the 6 bolts.

13. Install the breather.

75

Snap Ring

76

Oil Seal

77

Spiral Pin

78

Front Adapter

82

Sleeve Bearing

83

Needle Bearing

84

Input Shaft

Item

6 Bolts

Breather

Tightening Torque

28 - 48 Nm

8 - 20 Nm

TRANSFER CASE (PART TIME 4408)  5D1-29

Front Output Shaft

1. Position the output shaft in transfer case and install the

companion flange assembly, oil seal, washer and nut.

2. Holding the companion flange, tighten the nut.

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

111 Case

55

Output Shaft

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. Install the new pin, roller and retainer into the reduction

shift fork.

2. Press the pin, roller and retainer into the reduction spilt fork

bore completely.

Notice

Make sure that the cam roller turns freely.

3. Install the 2 fork facing on the reduction shift fork assembly.

4. Install the reduction shift fork onto the previously installed

reduction hub in the transfer case.

5. Install the output shaft spline into the reduction hub and

engage the output shaft end with input shaft bearing.

Notice

For installation of the output shaft, assemble

the oil pump temporarily.

5D1-30  TRANSFER CASE (PART TIME 4408)

Oil Pump

1. Install the pump front cover to be the ‘TOP’ mark down and

turn the cover to be the ‘TOP’ mark up when installed in
vehicle.

2. Install the 2 pump pins and spring to the output shaft.

Notice

Flat surface of the pins must point out and align the center
line of pins and spring.

3. Connect the hose coupling to the strainer coupling and

install the strainer foot into the transfer case slot.

Notice

The hose coupling must face the pump assembly.

4. Install the pump housing to be the 'REAR' mark up and seat

the 2 pump pins inside of the pump housing by moving
pump pins inward and compressing the spring.

5. Tighten the hose to pump housing by hose clamp.

6. Position the pump rear cover to be the ‘TOP REAR’ mark

up and located at the top of transfer case when installed in
vehicle. Position the pump retainer on the cover so that tab
on the retainer is in notch in the transfer case. Apply Loctite
to the bolts and tighten the bolts with turning the output
shaft by hand to make the pump pins move freely.

45

Shaft and Pump Assembly

46

Bolt

47

Pump Retainer

48

Rear Pump Cover

49

Hose Clamp

50

Hose Coupling

54

Pump Housing

52

Pump Pin

53

Spring

54

Front Pump Cover

55

Output Shaft

56

Strainer

40

Snap Ring

41

Spacer

42

Drive Sprocket

43

Driven Sprocket

44

Drive Chain

55

Output Shaft (Rear)

71

Output Shaft (Front)

Drive Chain

1. Position the drive sprocket to the rear output shaft end and

driven sprocket to the front output shaft end.

2. Install the drive chain onto the sprocket.

3. Holding each sprocket to be the drive chain tight and parallel

with transfer case, install the drive chain assembly to the
output shafts.

4. Rotate the driven sprocket slightly to engage splines on

the front output shaft.

5. Install the spacer to the front output shaft and insert the

snap ring into the shaft groove over spacer.

Tightening  Torque

4 - 8.5 Nm

TRANSFER CASE (PART TIME 4408)  5D1-31

Lockup Shift

1. Install the lockup hub and return spring to the lockup collar

and insert the snap ring.

2. Install the rail shaft through reduction shift fork assembly

previously installed and into the blind hole in case.

3. Engage the lockup fork into the 2WD/4WD groove and

check operation.

4. Install the shift collar hub to the output shaft spline.

5. Install the previously assembled electric shift cam and

assemble the clutch housing as follows.

!

Rotate the shift cam assembly to right so that the end of

the torsion spring contacts with reduction shift fork side.

!

Holding the rail shaft, lift up the fork assembly slightly.

Adjust electric shift cam assembly so that the roller on

reduction shift fork assembly is in groove in shift cam
and button on lockup fork is on cam end.

!

Install the clutch housing over shift collar hub and insert

the retaining ring into the clutch collar hub groove.

30

Retaining Ring

31

Clutch Housing

32

Shift Collar Housing

33

2WD/4WD
Lockup Assembly

34

Snap Ring

38

Rail Shaft

39

Lockup Fork

59

Reduction Shift Fork Assembly

100

Electric Shift Cam

101

Torsion Spring

35

Lockup Hub

36

Return Spring

37

Lockup Collar

38

Rail Shaft

39

Lockup Fork

55

Output Shaft