Daewoo Musso. Manual - part 312

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.