SSANGYONG KORANDO 1997 Service Repair Manual

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)

yyyy yyyy

yyyy yyyy

yyyy yyyy
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.

TRANSFER CASE (PART TIME - 4408) 5D2-39
SSANGYONG MY2002
KAA5D860
KAA5D870
Oil Pump
1. Install the pump front cover to be the “TOP” mark
down and turn the cover to be the “TOP” mark up
when installed in vehicle.
2. Install the 2 pump pins and spring to the output
shaft.
Notice: Flat surface of the pins must point out
and align the center line of pins and spring.
3. Connect the hose coupling to the strainer coupling
and install the strainer foot into the transfer case
slot.
Notice: The hose coupling must face the pump
assembly.
4. Install the pump housing to be the ‘REAR’ mark
up and seat the 2 pump pins inside of the pump
housing by moving pump pins inward and
compressing the spring.
5. Tighten the hose to pump housing by hose clamp.
6. Position the pump rear cover to be the TOP REAR
mark up and located at the top of transfer case
when installed in vehicle. Position the pump
retainer on the cover so that tab on the retainer is
in notch in the transfer case. Apply Loctite to the
bolts and tighten the bolts with turning the output
shaft by hand to make the pump pins move freely.
Installation Notice
Tightening Torque4 - 8.5 Nm
(35 - 75.5 lb-in)
Drive Chain
1. Position the drive sprocket to the rear output shaft
end and driven sprocket to the front output shaft
end.
2. Install the drive chain onto the sprocket.
3. Holding each sprocket to be the drive chain tight
and parallel with transfer case, install the drive
chain assembly to the output shafts.
4. Rotate the driven sprocket slightly to engage
splines on the front output shaft.
5. Install the spacer to the front output shaft and insert
the snap ring into the shaft groove over spacer.

SSANGYONG MY2002
5D2-40 TRANSFER CASE (PART TIME - 4408)
KAA5D880
KAA5D890
Lockup Shift
1. Install the lockup hub and return spring to the
lockup collar and insert the snap ring.
2. Install the rail shaft through reduction shift fork
assembly previously installed and into the blind
hole in case.
3. Engage the lockup fork into the 2WD/4WD groove
and check operation.
4. Install the shift collar hub to the output shaft spline.
5. Install the previously assembled electric shift cam
and assemble the clutch housing as follows.
Rotate the shift cam assembly to right so that
the end of the torsion spring contacts with
reduction shift fork side.
Holding the rail shaft, lift up the fork assembly
slightly.
Adjust electric shift cam assembly so that the
roller on reduction shift fork assembly is in
groove in shift cam and button on lockup fork
is on cam end.
Install the clutch housing over shift collar hub
and insert the retaining ring into the clutch collar
hub groove.

TRANSFER CASE (PART TIME - 4408) 5D2-41
SSANGYONG MY2002
KAA5D900
Tightening Torque8 - 11 Nm
(71 - 97 lb-in)
Cover
1. Position the cover to be the open end up on the
work table.
2. Position the end of needle bearing to be
identification mark up and press into the cover
until upper end of bearing is 40.47 - 40.97 mm
below cover face that contacts with transfer case.
3. Press the ball bearing into the cover and install
the snap ring .
4. Install remaining parts as follows.
Install the 4 O-rings on the stud bolts of the
clutch coil assembly.
Install the clutch coil assembly inside the cover
and tighten 3 nuts.
Installation Notice
Install the bearing and motor bearing into the
cover.
KAA5D910
Cover Assembly
1. Install the return spring over rail shaft in the transfer
case.
2. Insert the magnet into the transfer case slot.
3. Apply 1.6 mm bead of Loctite RTV 598 to the
transfer case mounting surface.
Notice: For installation of cover, align the transfer
case with cover not to use excessive force.
4. Install the cover onto the transfer case as follows:
Align the cover bores with transfer case pins.
Align the cover bearings with output shafts.
Align the cover blind hole with rail shaft and
make sure that return spring is not cocked.