SsangYong Musso. Manual - part 524

TRANSFER CASE (TOD)  5D2-43

Disassembly Procedure

1. Disconnect transfer case from vehicle

2. Using a 30mm thin-wall socket, first remove the rear output

nut, output shaft yoke washer, oil seal then the case flange.

Installation Notice

27

Nut

28

Washer

30

Case Flange

Tightening  Torque

137 - 196 Nm

3. Disconnect shift motor/clutch coil connector and speed

sensor connector from upper bracket of transfer case.

Notice

When disconnect connector, pull forwards grasping
connector housing.

4. Remove outer tube on speed sensor connector.

5. Remove wire supporting cape back side of speed sensor

connector.

6. Disconnect pin of clutch coil wire (yellow) from speed sensor

connector (white 7 pin) using long-nose plier.

7. Remove shift motor.

Notice

When remove shift motor, pay attention to the location of
triangular slot and shaft in transfer case inside motor.

8. Disconnect front and rear speed sensor.

5D2-44  TRANSFER CASE (TOD)

9.

Remove the bolts that retain the front case to the
rear case. Make sure that the front case is facing
downward so that the rear cover is facing upwards.
Pry on the bosses and separate the front case from
the rear case. Remove all traces of gasket sealant
from the mating surfaces of the front case and rear
case.

10. If the speedometer drive gear is to be replaced, first

remove the flange seal by prying and pulling the
curved-up lip of the flange seal. Do not damage the
bearing, bearing cage or case. Remove and discard
the flange seal. Remove the speedometer drive gear
and upper tone wheel.

69

Yoke to Flange Seal

75

Snap Ring

76

Bearing

77

Speedometer Drive Gear

79

Upper Tone Wheel

40

Clutch Coil

40a

Clutch Coil Retaining Bolts

40b

Wire

11. If the rear output shaft bearing requires replacing, remove

the internal snap ring that retains the bearing in the bore.
From the outside of the case, drive out the bearing.

12. Remove the three nuts and washers retaining the clutch

coil assembly to the rear case. Pull the assembly, along
with the O-ring and wire, from the case.

13. Remove bearing assembly from output shaft.

Remove the clutch housing from the output shaft.

Remove the balls and apply cam and wave washer from
the output shaft.

Remove snap ring from output shaft. Remove clutch pack
assembly from output shaft.

25

Ball

26

Cam and Coil Assembly

TRANSFER CASE (TOD)  5D2-45

19

Clutch Pack Assembly

22

Snap Ring

23

Wave Washer

24

Apply Cam

14. Remove the chain, driven sprocket and drive sprocket

as an assembly.

15. Remove thrust washer from output shaft.

16. Remove the magnet from the slot in the front of the case

bottom. Remove the output shaft and oil pump as an
assembly.

Notice

If there is removal resistance, do not pound or use force
to disassemble the pump.

17. If required, to remove the pump from the output shaft,

rotate the pump to align.

18. Pull out the shift rail.

18

Drive Sprocket

58

Drive Chain

59

Driven Sprocket

12

Rear Output Shaft

16

Oil Pump

61

Magnet

19. Remove the helical cam from the front case. If required,

remove the helical cam, torsion spring and sleeve from
the shaft.

20. Remove the high-low range shift fork and collar as an

assembly.

21. Expand the tangs of the large snap ring in the case. With

the input shaft against a bench, push the case down and
slide the main drive gear bearing retainer off the bearing.
Lift the input shaft and front planet from the case.

22. If required, remove the oil seal from the case by prying

and pulling on the curved-up lip of the oil seal. Do not
damage the bearing, bearing cage or case.

5D2-46  TRANSFER CASE (TOD)

23. Remove the internal snap ring from the planetary carrier

and separate the front planet from the input shaft.

24. Remove the external snap ring from the input shaft. Place

the input shaft in a vise and remove the bearing. Remove
the thrust washer, thrust plate and the sun gear off the
input shaft.

25. Inspect the bushing and needle bearing in the end of the

input shaft for wear or damage.

Notice

Under normal use, the needle bearing and bushing should
not require replacement. If replacement is required, the
bushing and needle bearing must be replaced as a set.

26. If replacement of the needle bearing and bushing is

required, press the bearing and bushing is required, press
the bearing and bushing out as follows:

a. Position the input shaft on Axle Bearing/Seal plate,and

using Pinion Bearing Cone Replacer as a spacer.

b. Insert Input Shaft Bearing Remover into the input shaft

so it is resting on top of the bearing cage.

c. Tighten the actuator pin until it stops, then press the

bearing and bushing out together.

6

Input Shaft

8

Bearig

01

Pinion Bearing Cone Remover

02

Compress the Dowel

27. If required, remove the front yoke to flange seal by prying

and pulling on the curved-up lip of the yoke to flange seal.
Do not damage the bearing, bearing cage or case.

28. If required, remove the internal snap ring retaining the

front output shaft ball bearing and remove the bearing.