Daewoo Musso. Manual - part 298

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

5D1-34  TRANSFER CASE (PART TIME 4408)

External Electric Shift

1. Align the motor with shift shaft and position the motor

assembly onto the cover.

2. Install the motor to the shift shaft and contact cover androtate

the motor clockwise direction to check correctengagement.

6

Bolt

7

Washer

8

Bolt

9

Sensor and Harness Bracket

10

Sensor Assembly

14

Speed Sensor

12

O-ring

13

Motor Assembly

25

Cover

13

Motor Assembly

103

Shift Shaft

3. Insert the 0-ring on the speed sensor speed sensor

assembly to the cover.

4. Install the bracket to the motor assembly and tighten 3bolts.

Tightening Torque

8 -11 Nm