SSANGYONG MUSSO 2003 Service Manual

5D2-42 TRANSFER CASE (TOD)1 Bearing
2 Bushing
3 Carrier Assembly
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Output Shaft Thrust Washer
8 Bearing
9 Retaining Ring
10 Snap Ring
11 High-low Collar
12 Rear Output Shaft
13 Oil Strainer
14 Coupling Hose
15 Hose Clamp
16 Pump Assembly
17 Thrust Washer
18 Sprocket, Drive (24T)
19 Clutch Pack Assembly
20 Insulator Washer
21 Armature
22 Snap Ring
23 Wave Washer
24 Apply Cam
2 5 Ball
26 Cam and Coil Assembly
27 Nut, Metric
28 Output Shaft Yoke Washer
29 Oil Seal
30 Case Flange
31 Bolt
32 Upper Speed Sensor (Rear)
33 Nut
34 Washer
37 Bolt
38 Tag, Identification
39 Thrust Bearing
40 Clutch Coil Assembly
41 Fork, Reduction Shift 42 Shift Rail
43 Shaft, Shift
44 Spacer
45 Torsion Spring
46 Shift Cam
47 Transfer Case Shift Motor
48 Bolt
49 J-clip
50 Connector Retainer
51 Bolt
52 Support Stud
53 Lower Speed Sensor (Front)
54 Plug
55 Identification Decal
56 Cover
57 Tone Wheel, Lower
58 Chain, Drive
59 Sprocket, Driven (24T)
61 Magnet
62 Case
63 Case Flange and Output Shaft
64 Barb, Breather
68 Spiral Pin
69 Oil Seal
70 Pin, Dowel
71 Ring Gear
72 Retaining Ring
73 Snap Ring
74 Bearing
75 Snap Ring
76 Bearing
77 Speedometer Drive Gear
78 Facing, Shift Fork
79 Upper Tone Wheel
80 Oil Seal
81 Bearing Sleeve
82 Bearing

TRANSFER CASE (TOD) 5D2-43
Disassembly Procedure
1. Disconnect transfer case from vehicle
2. Using a 30mm thin-wall socket, first remove the rear outputnut, output shaft yoke washer, oil seal then the case flange.Installation Notice
27 Nut
28 Washer
30 Case Flange
Tightening Torque 137 - 196 Nm
3. Disconnect shift motor/clutch coil connector and speed sensor connector from upper bracket of transfer case. Notice
When disconnect connector, pull forwards grasping connector housing.
4. Remove outer tube on speed sensor connector.
5. Remove wire supporting cape back side of speed sensor connector.
6. Disconnect pin of clutch coil wire (yellow) from speed sensor connector (white 7 pin) using long-nose plier.
7. Remove shift motor.
Notice
When remove shift motor, pay attention to the location of
triangular slot and shaft in transfer case inside motor.
8. Disconnect front and rear speed sensor.

5D2-44 TRANSFER CASE (TOD)
9. Remove the bolts that retain the front case to therear case. Make sure that the front case is facing downward so that the rear cover is facing upwards. Pry on the bosses and separate the front case fromthe rear case. Remove all traces of gasket sealantfrom the mating surfaces of the front case and rearcase.
10. If the speedometer drive gear is to be replaced, first remove the flange seal by prying and pulling thecurved-up lip of the flange seal. Do not damage thebearing, bearing cage or case. Remove and discardthe flange seal. Remove the speedometer drive gearand upper tone wheel.
69 Yoke to Flange Seal
75 Snap Ring
76 Bearing
77 Speedometer Drive Gear
79 Upper Tone Wheel
40 Clutch Coil
40a Clutch Coil Retaining Bolts
40b Wire
11. If the rear output shaft bearing requires replacing, removethe internal snap ring that retains the bearing in the bore. From the outside of the case, drive out the bearing.
12. Remove the three nuts and washers retaining the clutch coil assembly to the rear case. Pull the assembly, alongwith the O-ring and wire, from the case.
13. Remove bearing assembly from output shaft. Remove the clutch housing from the output shaft. Remove the balls and apply cam and wave washer from the output shaft. Remove snap ring from output shaft. Remove clutch pack assembly from output shaft.
25 Ball
26 Cam and Coil Assembly

TRANSFER CASE (TOD) 5D2-45
19 Clutch Pack Assembly
22 Snap Ring
23 Wave Washer
24 Apply Cam
14. Remove the chain, driven sprocket and drive sprocketas an assembly.
15. Remove thrust washer from output shaft.
16. Remove the magnet from the slot in the front of the case bottom. Remove the output shaft and oil pump as an
assembly. NoticeIf there is removal resistance, do not pound or use force to disassemble the pump.
17. If required, to remove the pump from the output shaft, rotate the pump to align.
18. Pull out the shift rail.
18 Drive Sprocket
58 Drive Chain
59 Driven Sprocket
12 Rear Output Shaft
16 Oil Pump
6 1 Magnet
19. Remove the helical cam from the front case. If required,
remove the helical cam, torsion spring and sleeve from the shaft.
20. Remove the high-low range shift fork and collar as an assembly.
21. Expand the tangs of the large snap ring in the case. With the input shaft against a bench, push the case down and slide the main drive gear bearing retainer off the bearing.Lift the input shaft and front planet from the case.
22. If required, remove the oil seal from the case by prying and pulling on the curved-up lip of the oil seal. Do not damage the bearing, bearing cage or case.

5D2-46 TRANSFER CASE (TOD)
23. Remove the internal snap ring from the planetary carrierand separate the front planet from the input shaft.
24. Remove the external snap ring from the input shaft. Place the input shaft in a vise and remove the bearing. Remove
the thrust washer, thrust plate and the sun gear off theinput shaft.
25. Inspect the bushing and needle bearing in the end of the input shaft for wear or damage. NoticeUnder normal use, the needle bearing and bushing should not require replacement. If replacement is required, thebushing and needle bearing must be replaced as a set.
26. If replacement of the needle bearing and bushing is required, press the bearing and bushing is required, pressthe bearing and bushing out as follows:
a. Position the input shaft on Axle Bearing/Seal plate,andusing Pinion Bearing Cone Replacer as a spacer.
b. Insert Input Shaft Bearing Remover into the input shaft so it is resting on top of the bearing cage.
c . Tighten the actuator pin until it stops, then press the bearing and bushing out together. 6 Input Shaft
8 Bearig
01 Pinion Bearing Cone Remover
02 Compress the Dowel
27. If required, remove the front yoke to flange seal by prying and pulling on the curved-up lip of the yoke to flange seal. Do not damage the bearing, bearing cage or case.
28. If required, remove the internal snap ring retaining the front output shaft ball bearing and remove the bearing.

TRANSFER CASE (TOD) 5D2-47
Assembly Procedure Assembly
Before assembly, lubricate all parts with Automatic Transmission Fluid or equivalent.
1. If removed, drive the bearing into the front output case bore.Drive the bearing in staight, making sure it is not cocked in the bore. Install the internal snap ring that retains the bearing to the front case.
2. If removed, install the front yoke to flange seal in the front case bore.
3. If removed, install the yoke to flange seal into the mounting adapter bore.
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Thrust Washer
8 Bearing
9 External Snap Ring
10 Internal Snap Ring
4. If the input shaft needle bearing and bushing were removed,
install a new bearing and bushing as detailed in the following steps: Press a new needle bearing, then a new bushing in the input shaft as follows:
a. Position the input shaft on Axle Bearing/Seal Plate or equivalent, and Pinion Bearing Cone Replacer as a
spacer.
b. Press a new needle bearing into the end of the input shaft until it seats in the input shaft.
c. Press in a new bushing.
5. The recessed face of the sun gear and the snap ring groove on the bearing outer race should be toward the rear of thetransfer case. The stepped face of the thrust washer shouldface toward the bearing.
Slide the sun gear, thr ust plate and thrust washer into
position on the input shaft. Press the bearing over the input shaft. Install the external snap ring to the input shaft.

5D2-48 TRANSFER CASE (TOD)
6. Install the front planet to the sun gear and input shaft.Install the internal snap ring to the planetary carrier.
7. Place the tanged snap ring in the case. Expand snap ring with snap ring pliers and install planetary carrier assembly. Check installation by holding the case and carefully tappingthe face of the input shaft against a wooden block to makesure the snap ring is installed.
8. Remove all traces of gasket sealant from the front case and mounting adapter mating surfaces. Install a bead ofgasket sealant on the surface of the front case.
9. Install the high-low shift fork and high-low collar as an assembly into the front planet. Notice Make sure that the nylon wear pads are installed on the shift fork and snapped securely into place.
12 Rear Output Shaft
13 Oil Strainer
14 Coupling Hose
15 Hose Clamp
16 Pump Body
10. If new pump is used, align the flat of the output shaft and
the flat of the pump. Slide the pump onto the output shaft.
Do not disassemble oil pump. It is serviced only as an
assembly. Check the pump to make sure the pump
rotates freely.
Do not remove the plastic insert from the bore of the
new pump. Discard it after it slides out during pumpinstallation to the rear output shaft.
While turning the output shaft, prime the pump through
the oil filter pickup tube or housing inlet hole with clean
Automatic Transmission Fluid or equivalent.
11. Inspect the outside surfaces and bore of the oil pump. If there is no discoloration in the pump housing, gear or cover,and the pump bore and the lube holes of the output shaft show evidence of oil, the pump is working.

TRANSFER CASE (TOD) 5D2-49
12. Install the output shaft and oil pump in the input shaft.Make sure that the internal splines of the ouput shaft
engage the internal splines of the high-low shift collar. Make sure that the oil pump retainer arm and oil filter leg are inthe groove and slot of the front case.
13. Install the magnet in the slot in the front case just above the oil filter leg.
14. Install the front output shaft in the front case.
15. Install the thrust washer on the rear output shaft. Install the chain, drive sprocket and driven sprocket as an assembly over the output shaft. Notice
The driven sprocket (on the front output shaft) must
be installed with the marking REAR facing toward the rear case, if so marked.
Drive sprocket has a bushing pressed into it.
16. Install tone wheel onto the front output shaft. Make sure the spline on the tone wheel engages the spline on thefront output shaft.
17. Install clutch pack assembly onto the rear output shaft. Make sure the spline of the clutch pack engages to the spline of the sprocket.
18. Install snap ring onto the rear output shaft. Start the snap
ring over the spline and use the wave spring to seat the snap ring in the snap ring groove. If the snap ring will notinstall, the thrust washer inside the clutch pack may not
be seated properly. 1 2 Rear Output Shaft
1 6 Oil Pump
6 1 Magnet
1 2 Rear Output Shaft
1 3 Oil Strainer
1 6 Oil Pump
1 6 a Pump Retainer

5D2-50 TRANSFER CASE (TOD)
19. Install wave spring, insulator washer and armature. (Threeoffset slots must align with housing to be installed) NoticeThree slots on the thrust washer must be aligned with the three tabs on the clutch pack housing.
20. Install apply cam onto the rear output shaft, install three balls into the apply cam, install cam and coil housing assembly onto rear output shaft. Install thrust bearing assembly onto output shaft.
21. If removed, drive the front output shaft ball bearing into
the rear cover bore with Front Shaft Needle Bearing Replacer and Driver Handle.
22. If removed, install the rear output bearing in the rear case bore. Drive the bearing into the rear case bore with OutputShaft Bearing Replacer and Driver Handle. Make sure thatthe bearing is not cocked in the bore. Install the internalsnap ring that retains the bearing to the rear case.
23. Install the clutch coil from inside the rear case until the wire and studs extend through the cover. Install the washersand nuts and tighten. CAUTIONDo not kink or trap the wire while seating the clutch coil to the case.
24. Slide the spring spacer on the camshaft and position it beneath the drive tang. Place the torsion spring on thecamshaft. Position the first spring tang to the left of thecamshaft drive tang(View A). Wind the second spring tang clockwise past the drive tang(View B). Push the torsion spring and sleeve in as far as it will go (View C). This willseat the second spring tang on the right side of the drivetang. Install the helical cam and slide the drive tang betweenthe torsion spring tangs as far as it will go.

TRANSFER CASE (TOD) 5D2-51
25. Install the pin on the tang end of the helical cam into thehole 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. CAUTIONDo not bend the helical cam during installation to the front case because of possible damage to the pin at the tangend of the motor shaft.
26. Install the shift rail through the high-low shift fork and make sure that the reverse gear shift rail is seated in the frontcase bore.
27. Install upper and lower speed sensors into the cover. Feed the coil wire through the upper speed sensor wire shield.
2 8. Install upper tone wheel, speedometer gear and rear output seal. Use Output Shaft Seal Replacer and Driver orequivalent to install seal.
29. Coat the mating surface of the front case with a bead of Black Non-Acid Cure Silicone Rubber or equivalent.
30. The following procedure must be followed prior to installing the rear case onto the front case half:
a. Align the output shaft with the rear case output shaft bore.
b. 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 whilepushing down on the rear case.
Tightening Torque 25 - 37 Nm
31. Install the bolts retaining the case halves and tighten.