SSANGYONG MUSSO 1998 Workshop Repair Manual

5D2-44 TRANSFER CASE (TOD)
9. Remove the bolts that retain the front case to the
rear 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 from
the rear case. Remove all traces of gasket sealant
from the mating surfaces of the front case and rear
case.
10. If the speedometer drive gear is to be replaced, first
remove the flange seal by prying and pulling the
curved-up lip of the flange seal. Do not damage the
bearing, bearing cage or case. Remove and discard
the flange seal. Remove the speedometer drive gear
and 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, remove
the 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, along
with 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 sprocket
as 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.
Notice
If 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
61 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 carrier
and 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 the
input shaft.
25. Inspect the bushing and needle bearing in the end of the
input shaft for wear or damage.
Notice
Under normal use, the needle bearing and bushing should
not require replacement. If replacement is required, the
bushing 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, press
the bearing and bushing out as follows:
a. Position the input shaft on Axle Bearing/Seal plate,and
using 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 the
transfer case. The stepped face of the thrust washer should
face toward the bearing.
Slide the sun gear, thrust 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 tapping
the face of the input shaft against a wooden block to make
sure the snap ring is installed.
8. Remove all traces of gasket sealant from the front case
and mounting adapter mating surfaces. Install a bead of
gasket 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.
lDo not disassemble oil pump. It is serviced only as an
assembly. Check the pump to make sure the pump
rotates freely.
lDo not remove the plastic insert from the bore of the
new pump. Discard it after it slides out during pump
installation to the rear output shaft.
lWhile 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 in
the 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
lThe driven sprocket (on the front output shaft) must
be installed with the marking REAR facing toward the
rear case, if so marked.
lDrive 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 the
front 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 not
install, the thrust washer inside the clutch pack may not
be seated properly.
1 2 Rear Output Shaft
1 6 Oil Pump6 1 Magnet 1 2 Rear Output Shaft
1 3 Oil Strainer
1 6 Oil Pump
16a Pump Retainer

5D2-50 TRANSFER CASE (TOD)
19. Install wave spring, insulator washer and armature. (Three
offset slots must align with housing to be installed)
Notice
Three 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 Output
Shaft Bearing Replacer and Driver Handle. Make sure that
the bearing is not cocked in the bore. Install the internal
snap 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 washers
and nuts and tighten.
CAUTION
Do 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 the
camshaft. Position the first spring tang to the left of the
camshaft 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 will
seat the second spring tang on the right side of the drive
tang. Install the helical cam and slide the drive tang between
the 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 the
hole 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.
CAUTION
Do not bend the helical cam during installation to the front
case because of possible damage to the pin at the tang
end 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 front
case bore.
27. Install upper and lower speed sensors into the cover. Feed
the coil wire through the upper speed sensor wire shield.
28. Install upper tone wheel, speedometer gear and rear output
seal. Use Output Shaft Seal Replacer and Driver or
equivalent 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 while
pushing down on the rear case.
Tightening Torque 25 - 37 Nm 31. Install the bolts retaining the case halves and tighten.

5D2-52 TRANSFER CASE (TOD)
32. Install shift shaft oil seal if it is not installed.
33. Using pliers equipped with soft jaws, rotate the triangular
shaft so it is aligned with the triangular slot in the transfer
case shift motor. If triangular shaft will not rotate, rotate
the rear output shaft.
34. Slightly loosen the two nuts that attach the slotted support
bracket to the end of the motor house.
35. Apply Black Non-Acid Cure Silicone Rubber or equivalent
to motor housing base and install on transfer case.
36. Install the transfer case shift motor and three bolts along
with speed sensor wire harness bracket and tighten.
Notice
The wire harness must be routed as shown to provide
clearance and to prevent the wire harness from grounding
the damper.
37. Holding the slotted support bracket tight against the motor
housing end, secure the bracket to the transfer case,
tightening the bolt with lockwasher to 8-11 Nm (72-96 lb-
in).
38. Retighten the two nuts that attach the slotted support
bracket to the end of the motor.
39. Install the clutch coil wire terminal and sensor wires.

TRANSFER CASE (TOD) 5D2-53
40. Install the rear case flange on the output shaft. Install the
rubber seal, output shaft yoke washer and nut. Tighten
the nut.
Tightening Torque 137 - 196 Nm
41. Install the drainplug and tighten.
42. Fill the transfer case with 1.4 liters of Automatic
Transmission Fluid or equivalent.
Notice
Fluid level should be just below the filler plug hole.
Tightening Torque 19 - 30 Nm
Tightening Torque 19 - 30 Nm 43. Install the fill pulg and tighten.
44. Install the transfer case as outlined in removal and
Installation, transfer case in the section.
Notice
Make sure proper drain and fill plugs are installed if case
is replaced.