SsangYong Musso. Service manual - part 510

5D1-24  TRANSFER CASE (PART TIME 4408)

Description

Repair

Description

Repair

Corner chip

at drive face

Edge chip

at drive face

Corner chip

at coast face

Side edge chip

at drive face

Chip within

contact pattern

Chip completely

through tooth

TRANSFER CASE (PART TIME 4408)  5D1-25

Electric Shift Cam Parts

1. Insert the spacer into torsion spring.

2. Insert the end of the shift shaft into the spacer smoothly.

100

Electric Shift Cam

101

Torsion Spring

102

Spacer

103

Shift Shaft

Assembly Procedure

General Information

1. Use special tools during assembly of oil seals and bearings.

2. Lubricate bearings, oil seals and bushings before assembly.

105

Case Assembly

106

Oil Seal

107

Retaining Ring

108

Ball Bearing

109

Pin

110

Ring Gear

111

Case

106

Oil Seal

109

Pin

110

Ring Gear

111

Case

Transfer Case

1. If the ring gear was removed, align the outer diameter of

the new replaced ring gear with transfer case and assemble
it.

2. Insert the pin.

3. Insert the ball bearing to the case and install the retaining

ring.

4. Install the new oil seal by pressing into the case.

5. Make sure that all parts are correctly and firmly installed

into the case.

5D1-26  TRANSFER CASE (PART TIME 4408)

101

Torsion Spring

102

Spacer

103

Shift Shaft

3. Slide the torsion spring and spacer to the left of the shift

shaft and position the end of the first spring to fix on the
drive tang.

4. Push the end of the second spring to right and fix it on the

drive tang.

101

Torsion Spring

102

Spacer

103

Shift Shaft

5. Push the torsion spring and spacer together back them

completely.

6. Slide the electric shift cam onto the shift shaft.

7. Install the electric shift cam assembly into the transfer case

after installation of the shift fork.

101

Torsion spring

102

Spacer

103

Shift Shaft

TRANSFER CASE (PART TIME 4408)  5D1-27

Adapter, Input Shaft and Carrier

72 Breather
73 Bolt
74 Adapter Assembly
75 Snap Ring
76 Oil Seal
77 Spiral Pin
78 Front Adapter
79 Retaining Ring
80 Bearing
81 Input Shaft Assembly

1. Place the planet carrier assembly on work bench to be the

retaining ring mounting groove upward.

2. Install the sun gear with the hub end up into the planet

carrier assembly and rotate the sun gear to make sure that
gears are fully engaged.

3. Align the tabs and install the thrust plate into the planet

carrier assembly.

4. Install the retaining ring to the planet carrier assembly.

5. Press the needle bearing into the input shaft and press the

new sleeve bearing into the input shaft assembly.

82 Sleeve Bearing
83 Needle Bearing
84 Input Shaft
85 Thrust Washer

86 Carrier Gear Assembly
87 Retaining Ring
88 Thrust Plate
89 Sun Gear
90 Planet Carrier Assembly

111 Case