Daewoo Korando. Manual - part 294

5D1-26  TRANSFER CASE (PART TIME 4408)

101

Torsion Spring

102

Spacer

103

Shift Shaft

3. Slide the torsion spring and spacer to the left of the shift

shaft and position the end of the first spring to fix on the
drive tang.

4. Push the end of the second spring to right and fix it on the

drive tang.

101

Torsion Spring

102

Spacer

103

Shift Shaft

5. Push the torsion spring and spacer together back them

completely.

6. Slide the electric the electric shift cam onto the shift shaft.

7. Install the electric shift cam assembly into the transfer case

after installation of the shift fork.

101

Torsion spring

102

Spacer

103

Shift Shaft

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. Press the deflector onto yoke.

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

companion flange assembly, oil seal, washer and nut.

3. Holding the companion flange, tighten the nut.

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