SsangYong Korando II (1996-2006 year). Manual - part 357

SSANGYONG  MY2002

5D2-28  TRANSFER CASE (PART TIME - 4408)

KAA5D500

KAA5D510

KAA5D520

KAA5D530

•

2WD/4WD Lock Up Assembly Component.

(37) Snap Ring

(38) Lock up Hub

(39) Return Spring

(40) Lock up Collar

4. Remove the snap ring from the front output driven

sprocket and separate the snap ring and the
spacer.

5. Remove the driving sprocket, the driven sprocket

and the driving chain from the front/rear output
shaft.

6. Remove the oil pump assembly and the magnetic

from the output shaft.

TRANSFER CASE (PART TIME - 4408)  5D2-29

SSANGYONG  MY2002

KAA5D540

KAA5D550

•

Remove the bolt and the retainer. Separate the
output shaft and rear pump cover.

•

Remove the hose clamp and remove the hose
coupling cover from the pump housing.

•

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

•

Remove two pump pins and the spring from
the output shaft.

•

Separate the front pump and remove the output
shaft.

KAA5D560

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.

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.

SSANGYONG  MY2002

5D2-30  TRANSFER CASE (PART TIME - 4408)

KAA5D570

KAA5D580

Adapter, Input Shaft and Carrier Gear

1. Remove the breather.

2. After removing 6 bolts, remove the front adopter

by separating the adapter sealer bond from the
case using a screw driver.

Notice: Be careful not to damage the contacting
surface of the case and adapter.

3. Remove the adapter assembly, input shaft

assembly and carrier gear assembly.

4. Remove the snap ring and oil seal from the front

adapter.

5. After removing snap ring, pull out the bearing and

thrust washer from the input shaft assembly and
separate the input shaft assembly from the carrier
gear assembly.

6. Remove the needle bearing and sleeve bearing

from the input shaft assembly.

7. Remove the retaining ring, thrust plate rind sun

gear from the planet carrier assembly.

Notice:  Do not disassemble the planet carrier
assembly.

Transfer Case Assembly (Front)

1. Remove the oil seal.

2. Remove the retaining ring and the ball bearing.

3. Remove the pin from the transfer case.

Notice: Be careful not to give any damage to the
case for removing the pin.

4. Remove the ring gear from the case using the

press.

Notice: Replace new part for installation.

TRANSFER CASE (PART TIME - 4408)  5D2-31

SSANGYONG  MY2002

Cleaning Procedure

Notice:  Before cleaning, check the magnet for the
presence of metal particles which indicate internal
chipping of the transfer case.

1. Using cleaning solvent, clean the residual oil and

dirt deposits.

Notice: During cleaning, be careful not to damage
the metal surfaces.

2. After cleaning, dry the parts with low pressure(Max.

20 psi) compressed air.

3. Lubricate the ball bearings and needle bearings

with transfer case oil after cleaning.

Notice: Protect the lubricated bearings from dust.

Inspection Procedure

1. Visually check the all removed parts.

Notice: Always replace the hose coupling, O-ring
and oil seal with new parts.

2. Inspection Terms

•

Burr : Local rise of material forming protruding
sharp edge

•

Chip : An area from which a small fragment has
been broken off or cut

•

Crack : Surface break of line nature indicating
partial or complete separation of material.

•

Excessive wear : Heavy or obvious wear beyond
e x p e c t a t i o n s   c o n s i d e r i n g   c o n d i t i o n s   o f
operation.

•

Indentation : Displacement of material caused
by localized heavy contact.

•

Galling : Breakdown of metal surface due to
excessive friction between parts. Particles of
the softer material are torn loose and welded to
the harder material.

•

Nick : Local break or notch, usually displacement
of material rather than loss.

•

Scoring : Tear or break in metal surface from
contact under abnormal pressure.