SsangYong Rexton. Manual - part 609

SSANGYONG  Y200

5D2-84  TRANSFER CASE - TOD

YAD5D650

YAD5D660

YAD5D670

YAD5D680

28. Install apply cam onto the rear output shaft,

29. Install three balls into the apply cam.

30. Install cam and coil housing assembly onto rear

output shaft.

31. Install thrust bearing assembly onto output shaft.

35. Install the clutch coil from inside the rear case until

the wire and studs extend through the cover.

Notice: Do not kink or trap the wire while seating
the clutch coil to the case.

36. Install the washers and nuts and tighten.

Installation Notice

33. If removed, install the rear output bearing in the

rear case bore. Drive the bearing into the rear
case bore with Output Shaft Bearing Replacer and
Driver Handle. Make sure that the bearing is not
cocked in the bore.

34. Install the internal snap ring that retains the bearing

to the rear case.

32. If removed, drive the front output shaft ball bearing

into the rear cover bore with Front Shaft Needle
Bearing Replacer and Driver Handle.

Tightening Torque

8 - 11 N•m

 (71 - 97 lb-in)

TRANSFER CASE - TOD  5D2-85

SSANGYONG  Y200

43a

YAD5D690

YAD5D700

YAD5D710

YAD5D720

37. Slide the spring spacer on the camshaft and

position it beneath the drive tang.

38. Place the torsion spring on the camshaft. Position

the first spring tang to the left of the camshaft drive
tang.

42. Install the pin on the tang end of the helical cam

into the hole in the front case. Position the torsion
spring tangs so that they are pointing toward the
top side of the transfer case and just touching the
high-low shift fork.

Notice: Do not bend the helical cam during
installation to the front case because of possible
damage to the pin at the tang end of the motor
shaft.

43. Install the shift rail through the high-low shift fork

and make sure that the reverse gear shift rail is
seated in the front case bore.

40. Push the torsion spring and sleeve in as far as it

will go.

41. Install the helical cam and slide the drive tang

between the torsion spring tangs as far as it will
go.

39. Rotate the second spring tang clockwise past the

drive tang.

SSANGYONG  Y200

5D2-86  TRANSFER CASE - TOD

YAD5D730

YAD5D740

44. Install upper and lower speed sensors into the

cover. Feed the coil wire through the upper speed
sensor wire shield.

46. Coat the mating surface of the front case with a

bead of Black Non-Acid Cure Silicone Rubber or
equivalent.

47. The following procedure must be followed prior to

installing the rear case onto the front case half:

•

Align the output shaft with the rear case output
shaft bore.

•

Align the helical cam with the rear case motor
bore.

•

If difficulty is encountered with seating the rear
case, tap the rear output shaft with a sharp blow
using a rubber mallet in a direction away from
the triangular shaft while pushing down on the
rear case.

45. Install upper tone wheel, speedometer gear and

rear output seal. Use Output Shaft Seal Replacer
and Driver or equivalent to install seal.

TRANSFER CASE - TOD  5D2-87

SSANGYONG  Y200

YAD5D750

YAD5D760

YAD5D770

48. Install the bolts retaining the case halves and

tighten.

Installation Notice

Tightening Torque

25 - 37 N•m

 (8 - 27 lb-ft)

49. Install shift shaft oil seal if it is not installed.

50. Using pliers equipped with soft jaws, rotate the

triangular shaft so it is aligned with the triangular
slot in the transfer case shift motor.

Notice: If triangular shaft will not rotate, rotate the
rear output shaft.

51. Tighten manually the two nuts that attach the

slotted support bracket to the end of the motor
house.

52. Apply Black Non-Acid Cure Silicone Rubber or

equivalent to motor housing base and install on
transfer case.

53. Install the transfer case shift motor and three bolts

along with speed sensor wire harness bracket and
tighten.

Installation Notice

Tightening Torque

8 - 11 N•m

 (71 - 97 lb-in)