SsangYong Korando II (1996-2006 year). Manual - part 350

SSANGYONG MY2002

5D1-76  TRANSFER CASE

KAA5D440

KAA5D430

KAA5D420

KAA5D410

11. Install the output shaft and oil pump in the input

shaft

Notice:

•

If a new pump is used, align the flat of the
output shaft and the flat of the pump. Slide the
pump onto the rear output shaft.

•

Do not remove the plastic insert from the bore
of the new pump. Discard it after it slides out
during pump installation to the rear output shaft.

•

While turning the output shaft, prime the pump
through the oil filter pickup tube or housing inlet
hole with clean ATF or equivalent.

12. Install the magnet in the slot in the front case just

above the oil filter leg.

13. Install the thrust washer on the rear output shaft.

14. Install the chain, drive sprocket and driven

sprocket as an assembly over the output shafts.

Notice: The driven sprocket on the front output
shaft must be installed with the marking REAR
facing toward the rear case, if so marked.

15. Install front propeller shaft speed sensor tooth

wheel onto the front output shaft.

19. Install cam and coil housing assembly onto rear

out-put shaft.

20. Install thrust bearing assembly onto output shaft.

21. Install the rear output shaft bearing, if removed.

Notice: Make sure that the bearing is not cocked
in the bore.

22. Install the internal snap ring that retains the

bearing to the rear case.

16. Install clutch pack assembly onto the rear output

shaft

17. Install snap ring onto the rear output shaft.

Notice: If the snap ring will not install, the thrust
washer inside the clutch pack may not be seated
properly.

18. Install wave spring, apply cam and balls.

TRANSFER CASE  5D1-77

SSANGYONG MY2002

KAA5D420

KAA5D590

23. Install the clutch coil and tighten three bolts.

Installation Notice

Caution: Do not kink or trap the wire while
seating the clutch coil to the case.

24. Install the pin on the tang end of the helical cam

into the hole in the front case.

25. 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 rear propeller shaft speed sensor toothed

wheel, vehicle speedometer gear and rear output
shaft seal if removed. Use oil seal installer or equiv-
alent.

Tightening Torque

8 - 11 N•m

 (6 - 8  lb-ft)

SSANGYONG MY2002

5D1-78  TRANSFER CASE

31. Install the rear output shaft flange on rear output

shaft. Install the rubber seal, output shaft yoke
washer and nut. Tighten the nut and calk the nut
on the flat area.

Installation Notice

32. Install the shift motor. Refer to the “Shift Motor”

in this section.

33. Insert the brown wire and pin to speed sensor con-

nect and assemble the connector. Refer to “Front
and Rear Propeller Shaft Speed Sensors” in this
section.

34. Install the drain plug and tighten the drain plug.

Installation Notice

35. Fill the transfer case with 1.4 liters of ATF or equiva

lent.

Notice: Fluid level should be just below the filler
plug-hole.

36. Install the filler plug and tighten.

Installation Notice

37. Install the transfer case to the vehicle. Refer to

“Transfer Case” in the section.

5D380

28. Coat the mating surface of the front case with a

bead of black non-acid cure silicone rubber or
equivalent.

29. Assemble the rear case on to front case.

Notice: Align the rear output shaft with the rear
case output shaft bore. Align the helical cam with
the rear case motor bore.

30. Install the bolts retaining the case halves and

tighten the bolts.

Installation Notice

Tightening Torque

27 - 35 N•m

 (20 - 26 lb-ft)

Tightening Torque

140 - 200 N•m

 (103 - 148 lb-ft)

Tightening Torque

19 - 30 N•m

 (14 - 22 lb-ft)

Tightening Torque

4 - 6 N•m

 (35 - 53 lb-in)

SECTION 5D2

TRANSFER CASE (PART TIME - 4408)

TABLE OF CONTENTS

General Infromation and Operation .................. 5D2-2

4WD Operation Overview ................................... 5D2-2

System Structure ............................................... 5D2-3

2H Mode (Rear Wheel Drive) .............................. 5D2-5

4H Mode (4WD Drive - High Speed) ................... 5D2-6

4H Mode (4WD Drive - Low Speed) .................... 5D2-7

System Description ........................................... 5D2-8

Specifications .................................................... 5D2-9

Diagnostic Infromation and Procedures .......... 5D2-10

General Diagnosis ........................................... 5D2-10

Self-Diagnosis Test .......................................... 5D2-11

Diagnostic Diagram ......................................... 5D2-15

Component Locator ......................................... 5D2-16

Cross Sectional View ....................................... 5D2-16

Transfer Case Assembly .................................. 5D2-17

Disassembly and Assembly ............................ 5D2-18

Maintenance and Repair ................................. 5D2-20

On-Vehicle Service ............................................. 5D2-20

Maintenance of Transfer Case Lubricant ........... 5D2-20

4H and 4L Indicator ......................................... 5D2-21

TCCU Inspection ............................................. 5D2-21

Transfer Case Assembly .................................. 5D2-22

TCCU .............................................................. 5D2-24

Unit Repair ........................................................ 5D2-25

Disassembly Procedure ................................... 5D2-25

Assembly Procedure ....................................... 5D2-35