SSANGYONG MUSSO 2003 Service Manual

TRANSFER CASE (PART TIME 4408) 5D1-19
<Front Output Assembly>
1. Holding the companion flange, remove the nut and washerand then remove the companion flange and oil seal.
2. Remove the output shaft.
65 Nut
66 Washer
67 Oil Seal
70 Companion Flange
71 Output Shaft (front)
111 Case
57 Reduction Hub
58 Shift Fork Facing
59 Reduction Shift Fork Assembly
60 Roller Pin and Retainer Assembly
61 Retainer
62 Pin
63 Roller Cam
64 Reduction Shift Fork
<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.

5D1-20 TRANSFER CASE (PART TIME 4408)
<Adapter, Input Shaft and Carrier Gear>
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. 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. NoticeBe 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 andseparate 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.
82 Sleeve Bearing
83 Needle Bearing
84 Input Shaft
85 Thrust Bearing
86 Carrier Gear Assembly
87 Retaining Ring
88 Thrust Plate
89 Sun Gear
90 Planet Carrier Assembly
111 Case

TRANSFER CASE (PART TIME 4408) 5D1-21
<Electric Shifts Cam Parts>
1. Remove the electric shift cam parts from the case assembly.
2. Separate the electric shift cam from the shift shaft.
3. Holding the shift shaft in a vise, remove the torsion springand spacer from the shift shaft using a screw driver.
100 Electric Shift Cam
101 Torsion Spring
102 Spacer
103 Shift Shaft
111 Case
105 Transfer Case Assembly
106 Oil Seal
107 Retaining Ring
108 Ball Bearing
119 Pin
110 Ring Gear
111 Case
<Case Assembly>
1. Remove the oil seal.
2. Remove the retaining ring and bearing.
3. Remove the pin from the transfer case.
Notice Be careful not to damage the pin.
4. Using a press, remove the ring gear from the case.

5D1-22 TRANSFER CASE (PART TIME 4408) Cleaning Procedure Notice Before cleaning, check the magnet for thepresence of metal particles which indicate internalchipping of the transfer case.
1. Using cleaning solvent, clean the residual oil and dirtdeposits.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. NoticeProtect 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 materialare 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.
Step wear : Heavy wear that produces a step that can
be seen or felt between adjacent contact and noncontactsurfaces.
Uneven wear : Condition of localized, unevenly distributed
wear Includes hollows, shiny spots, uneven polish and other visual indications.

TRANSFER CASE (PART TIME 4408) 5D1-23
3. Specific Inspection Referring to normal gear tooth face, specifically inspect
the uneven wear and chips of gear tooth.
Replace or repair if necessary.
4. Inspection of Contact Patterns
Description NormalAbnormal
Normal Wear
End Face Wear
Traveling Face Wear Upper Face Wear
Lower Face Wear

5D1-24 TRANSFER CASE (PART TIME 4408)
Description Repair Description RepairCorner 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 thedrive 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 Carrier72 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 Washer86 Carrier Gear Assembly
87 Retaining Ring
88 Thrust Plate
89 Sun Gear
90 Planet Carrier Assembly
111 Case

5D1-28 TRANSFER CASE (PART TIME 4408)
6. Install the planet carrier assembly onto the input shaftand 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 ofsnap 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.
75 Snap Ring
76 Oil Seal
77 Spiral Pin
78 Front Adapter
82 Sleeve Bearing
8 3 Needle Bearing
8 4 Input Shaft
Item
6 Bolts
Breather Tightening Torque
28 - 48 Nm8 - 20 Nm