SsangYong Rexton. Manual - part 584

PART TIME - T/C  5D1-27

SSANGYONG  Y200

1

YAD5D460

YAD5D470

Transfer Case Assembly

1. Separate the shift motor shaft cam assembly and

the spring(1).

YAD5D480

YAD5D490

2. Remove the clutch housing assembly from the

output shaft.

•

Clutch Housing Component

(1) Retaining Ring

(2) Shift collar Hub

(3) Clutch Housing

•

Remove the shift cam from the shaft.

•

Fix the shaft at the vise with the cam removed
and remove the torsion bar using a driver.

3. Remove the 2WD/4WD lock up assembly, the lock

up fork and rail shaft from the output shaft.

SSANGYONG  Y200

5D1-28  PART TIME - T/C

YAD5D500

YAD5D510

YAD5D520

YAD5D530

•

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.

PART TIME - T/C  5D1-29

SSANGYONG  Y200

YAD5D540

YAD5D550

•

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.

YAD5D560

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  Y200

5D1-30  PART TIME - T/C

YAD5D570

YAD5D580

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.