SsangYong Musso. Manual - part 512

5D1-32  TRANSFER CASE (PART TIME 4408)

Cover

1. Position the cover to be the open end up on the work table.

2. Position the end of needle bearing to be identification mark

up and press into the cover until upper end of bearing is
40.47 - 40.97mm below cover face that contacts with transfer
case.

3. Press the ball bearing into the cover and install the snap

ring .

4. Install remaining parts as follows.

!

Install the 4 O-rings on the stud bolts of the clutch coil

assembly.

!

Install the clutch coil assembly inside the cover and

tighten 3 nuts.

18

Oil Seal

19

Bushing

20

Nut

21

Clutch Coil Assembly

22

Snap Ring

23

Ball Bearing

24

Needle Bearing

25

Cover

Tightening  Torque

8 - 11 Nm

!

Install the bearing and motor bearing into the cover.

TRANSFER CASE (PART TIME 4408)  5D1-33

4. Install the cover onto the transfer case as follows :

!

Align the cover bores with transfer case pins.

!

Align the cover bearings with output shafts.

!

Align the cover blind hole with rail shaft and make sure

that return spring is not cocked.

29

Return Spring

38

Rail Shaft

55

Output Shaft

71

Front Output Shaft

103

Shift Shaft

109

Dowel Pin

Cover Assembly

14

Bolt

15

Wiring Clip

16

Identification Tag

17

Cover Assembly

26

Magnet

27

Speed Gear

28

Oil Seal

29

Return Spring

38

Rail Shaft

111

Case

1. Install the return spring over rail shaft in the transfer case.

2. Insert the magnet into the transfer case slot.

3. Apply 1.6mm bead of Loctite RTV 598 to the transfer case

mounting surface.

Notice

For installation of cover, align the transfer case with cover
not to use excessive force.

13

Motor Assembly

14

Bolt

15

Wiring Clip

16

Identification Tag

5. Tighten 9 bolts positioning identification tag and wiring clip.

6. Install the speed gear over output shaft spline in the cover

assembly.

7. Press the new oil seal into the cover assembly.

Tightening  Torque

28 - 48 Nm

5D1-34  TRANSFER CASE (PART TIME 4408)

External Electric Shift

1. Align the motor with shift shaft and position the motor

assembly onto the cover.

2. Install the motor to the shift shaft and contact cover androtate

the motor clockwise direction to check correctengagement.

6

Bolt

7

Washer

8

Bolt

9

Sensor and Harness Bracket

10

Sensor Assembly

14

Speed Sensor

12

O-ring

13

Motor Assembly

25

Cover

13

Motor Assembly

103

Shift Shaft

3. Insert the 0-ring on the speed sensor speed sensor

assembly to the cover.

4. Install the bracket to the motor assembly and tighten 3bolts.

Tightening Torque

8 -11 Nm

TRANSFER CASE (PART TIME 4408)  5D1-35

Companion Flange

1. Install the 2 plugs to the cover.

2. Install the companion flange, oil seal and washer.

3. Holding the companion flange, tighten the nut.

1

Nut

2

Washer

3

Oil Seal

4

Companion Flange

5

Plug

25

Cover

Notice

Apply Loctite 262 to nut before installation.

Tightening Torque

346 - 380 Nm