Daewoo Musso. Manual - part 297

TRANSFER CASE (PART TIME 4408)  5D1-27

Adapter, Input Shaft and Carrier

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. 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 Washer

86 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 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.

75

Snap Ring

76

Oil Seal

77

Spiral Pin

78

Front Adapter

82

Sleeve Bearing

83

Needle Bearing

84

Input Shaft

Item

6 Bolts

Breather

Tightening Torque

28 - 48 Nm

8 - 20 Nm

TRANSFER CASE (PART TIME 4408)  5D1-29

Front Output Shaft

1. Position the output shaft in transfer case and install the

companion flange assembly, oil seal, washer and nut.

2. Holding the companion flange, tighten the nut.

65 Nut
66 Washer
67 Oil Seal
70 Companion Flange
71 Output Shaft (Front)

111 Case

55

Output Shaft

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. 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.

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