Daewoo Korando. Manual - part 295

5D1-30  TRANSFER CASE (PART TIME 4408)

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.

45

Shaft and Pump Assembly

46

Bolt

47

Pump Retainer

48

Rear Pump Cover

49

Hose Clamp

50

Hose Coupling

54

Pump Housing

52

Pump Pin

53

Spring

54

Front Pump Cover

55

Output Shaft

56

Strainer

40

Snap Ring

41

Spacer

42

Drive Sprocket

43

Driven Sprocket

44

Drive Chain

55

Output Shaft (Rear)

71

Output Shaft (Front)

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.

Tightening  Torque

4 - 8.5 Nm

TRANSFER CASE (PART TIME 4408)  5D1-31

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.

l

Rotate the shift cam assembly to right so that the end of

the torsion spring contacts with reduction shift fork side.

l

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.

l

Install the clutch housing over shift collar hub and insert

the retaining ring into the clutch collar hub groove.

30

Retaining Ring

31

Clutch Housing

32

Shift Collar Housing

33

2WD/4WD
Lockup Assembly

34

Snap Ring

38

Rail Shaft

39

Lockup Fork

59

Reduction Shift Fork Assembly

100

Electric Shift Cam

101

Torsion Spring

35

Lockup Hub

36

Return Spring

37

Lockup Collar

38

Rail Shaft

39

Lockup Fork

55

Output Shaft

5D1-32  TRANSFER CASE (PART TIME 4408)

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 - 40.97mm 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.

l

Install the 4 O-rings on the stud bolts of the clutch coil

assembly.

l

Install the clutch coil assembly inside the cover and

tighten 3 nuts.

18

Oil Seal

19

Bushing

20

Nut

21

Clutch Coil Assembly

22

Snap Ring

23

Ball Bearing

24

Needle Bearing

25

Cover

Tightening  Torque

8 - 11 Nm

l

Install the bearing and motor bearing into the cover.

TRANSFER CASE (PART TIME 4408)  5D1-33

4. Install the cover onto the transfer case as follows :

l

Align the cover bores with transfer case pins.

l

Align the cover bearings with output shafts.

l

Align the cover blind hole with rail shaft and make sure

that return spring is not cocked.

29

Return Spring

38

Rail Shaft

55

Output Shaft

71

Front Output Shaft

103

Shift Shaft

109

Dowel Pin

Cover Assembly

14

Bolt

15

Wiring Clip

16

Identification Tag

17

Cover Assembly

26

Magnet

27

Speed Gear

28

Oil Seal

29

Return Spring

38

Rail Shaft

111

Case

1. Install the return spring over rail shaft in the transfer case.

2. Insert the magnet into the transfer case slot.

3. Apply 1.6mm 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.

13

Motor Assembly

14

Bolt

15

Wiring Clip

16

Identification Tag

5. Tighten 9 bolts positioning identification tag and wiring clip.

6. Install the speed gear over output shaft spline in the cover

assembly.

7. Press the new oil seal into the cover assembly.

Tightening  Torque

28 - 48 Nm