SsangYong Rexton. Manual - part 587

PART TIME - T/C  5D1-39

SSANGYONG  Y200

YAD5D860

YAD5D870

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.

Installation Notice

Tightening Torque

4 - 8.5 N•m

 (35 - 75.5 lb-in)

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.

SSANGYONG  Y200

5D1-40  PART TIME - T/C

YAD5D880

YAD5D890

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.

PART TIME - T/C  5D1-41

SSANGYONG  Y200

YAD5D900

Tightening Torque

8 - 11 N•m

 (71 - 97 lb-in)

Cover

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

work table.

2. P o s i t i o n   t h e   e n d   o f   n e e d l e   b e a r i n g   t o   b e

identification mark up and press into the cover
until upper end of bearing is 40.47 - 40.97 mm
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.

Installation Notice

•

Install the bearing and motor bearing into the
cover.

YAD5D910

Cover Assembly

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.

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.

SSANGYONG  Y200

5D1-42  PART TIME - T/C

5. Tighten 9 bolts positioning identification tag and

wiring clip.

Installation Notice

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 N•m

 (21 - 35 lb-ft)

YAD5D920

YAD5D930

YAD5D940

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 and rotate the motor clockwise direction to
check correct engagement.

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

the cover.

4. Install the bracket to the motor assembly and

tighten 3 bolts.

Installation Notice

Tightening Torque

8 - 11 N•m

 (71 - 97 lb-in)