transfer case SSANGYONG KORANDO 1997 Service Manual PDF

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
expectations considering conditions of
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.

SSANGYONG MY2002
5D2-32 TRANSFER CASE (PART TIME - 4408)
Step wear : Heavy wear that produces a step
that can be seen or felt between adjacent
contact and non-contact surfaces.
Uneven wear : Condition of localized, unevenly
distributed wear Includes hollows, shiny spots,
uneven polish and other visual indications.
3. Specific Inspection
Referring to normal gear tooth face, specifically
inspect the uneven wear and chips of gear tooth.
Replace or repair if necessary.
KAA5D590

TRANSFER CASE (PART TIME - 4408) 5D2-33
SSANGYONG MY2002
Normal Wear
End Face Wear
Traveling Face Wear
Upper Face Wear
Lower Face Wear
Normal Description Abnormal
KAA5D600
KAA5D610
KAA5D630KAA5D620
KAA5D640
KAA5D650 KAA5D660
4. Inspection of contact patterns
KAA5D670 KAA5D680

SSANGYONG MY2002
5D2-34 TRANSFER CASE (PART TIME - 4408)
Corner chip at drive face
Edge chip at drive face
Corner chip at coast face
Chip within contact pattern
Chip completely through
tooth
Side edge chip at drive face
Patterns DescriptionAction
KAA5D690
KAA5D700
KAA5D710
KAA5D720
5. Chip pattern of the gear face
KAA5D730
Repair
Repair
Repair
Replace
Replace
Replace
KAA5D740

SSANGYONG MY2002
5D2-24 TRANSFER CASE (PART TIME - 4408)

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KAA5D330
TCCU
1. Disconnect the negative terminal from the battery.
KAA5D340
KAA5D350
KAA5D360
2. Remove the TCCU connector.
3. Remove the TCCU mounting bolt and remove the
TCCU.
TCCU installation position : Under the driver’s
seat
4. Installation should follow the removal procedure
in the reverse order.
Notice: Be careful not to give any impact to the
TCCU body.
Installation Notice
Tightening Torque 10 Nm (89 lb-ft)

TRANSFER CASE (PART TIME - 4408) 5D2-35
SSANGYONG MY2002
KAA5D750
KAA5D760
KAA5D770
ASSEMBLY PROCEDURE
Use special tools during assembly of oil seals and
bearings.
Lubricate bearings, oil seals and bushings before
assembly.
Transfer Case Assembly
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.
Electric Shift Cam Parts
1. Insert the spacer into torsion spring.
2. Insert the end of the shift shaft into the spacer
smoothly.

SSANGYONG MY2002
5D2-36 TRANSFER CASE (PART TIME - 4408)
KAA5D780
KAA5D790
KAA5D800
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.
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.

TRANSFER CASE (PART TIME - 4408) 5D2-37
SSANGYONG MY2002
KAA5D810
KAA5D820
Adapter, Input Shaft and Carrier
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.
6. Install the planet carrier assembly onto the input
shaft and install the thrust washer. Press the
bearing over input shaft.
7. After pressing the bearing, install the retaining
ring.
8. Press the pin into the front adapter.
9. Slowly press the oil seal into the front adapter.
10. Install the front adapter assembly.
Notice: After installation, make sure that snap ring
is correctly installed into the groove.
11. Position the input shaft assembly over front cover
and engage into the bearing groove by expanding
the ends of snap ring.
12. Apply 1.6mm bead of sealant on the mounting
face for the transfer case and tighten the 6 bolts.
13. Install the breather.
Installation Notice
Tightening Torque
28 - 40 Nm
(21 - 30 lb-ft)
4 - 7 Nm
(35 - 62 lb-in)
Item
6 Bolts
Breather
Front Output Shaft
Cross Sectional View

SSANGYONG MY2002
5D2-38 TRANSFER CASE (PART TIME - 4408)
KAA5D830
KAA5D840
KAA5D850
Input Shaft
Cross Sectional View
Tightening Torque346 - 380 Nm
Front Output Shaft
1. Install the deflector on the yoke.
2. Position the output shaft in transfer case and install
the companion flange assembly, oil seal, washer
and nut.
3. Holding the companion flange, tighten the nut.
Installation Notice
Reduction Shift Parts
1. Install the new pin, roller and retainer into the
reduction shift fork.
2. Press the pin, roller and retainer into the reduction
spilt fork bore completely.
Notice: Make sure that the cam roller turns freely.
3. Install the 2 fork facing on the reduction shift fork
assembly.
4. Install the reduction shift fork onto the previously
installed reduction hub in the transfer case.
5. Install the output shaft spline into the reduction
hub and engage the output shaft end with input
shaft bearing.
Notice: For installation of the output shaft,
assemble the oil pump temporarily.