SsangYong Korando II (1996-2006 year). Manual - part 356

TRANSFER CASE (PART TIME - 4408)  5D2-23

SSANGYONG  MY2002

KAA5D300

KAA5D310

KAA5D320

7. Support the transfer case with jack and remove

the front and rear propeller shafts from the transfer
case.

Installation Notice

81 - 89 N•m

(60 - 66 lb-ft)

70 - 90 N•m

(52 - 66 lb-ft)

Tightening

Torque

Front

Rear

12 - 23 N•m

(9 - 17 lb-ft)

6 - 8 N•m

(53 - 71 lb-in)

Tightening Torque(1)

Tightening Torque(2)

Tightening Torque

35 - 60 N•m

 (26 - 44 lb-ft)

8. Remove the center mounting nuts and end sides

mounting bolts of the cross member and then
remove the cross member.

Installation Notice

9. Remove the transfer case by removing the bolts

attaching the transfer case to the transmission.

Installation Notice

Notice: Apply long-term grease to the inner spline
of the transfer case input shaft.

10. Installation should follow the removal procedure

in the reverse order.

TRANSFER CASE (PART TIME - 4408)  5D2-25

SSANGYONG  MY2002

KAA5D380

KAA5D390

UNIT REPAIR

DISASSEMBLY PROCEDURE

Shift Motor Assembly

1. Separate the harness bracket.

2. Remove the shift motor mounting bolt and remove

the shift motor assembly.

KAA5D400

KAA5D410

Companion Flange

1. Holding the companion flange, remove the nut and

washer and then remove the companion flange.

2. Remove the oil seal.

3. Remove the companion flange from the case

cover.

Case Cover Assembly

1. Remove the cover mounting bolts(9), and the case

mounting bolts(5).

Notice: Identification tag has information required
for ordering replacement parts, so be careful not
to lose it.

2. Using a driver, pry and disconnect the sealant

bond of the cover and required case.

SSANGYONG  MY2002

5D2-26  TRANSFER CASE (PART TIME - 4408)

KAA5D420

KAA5D430

3. Remove the clutch coil wiring from the connector.

4. Remove the clutch coil assembly mounting nut.

KAA5D440

KAA5D450

5. Remove the snap ring and pull out the ball bearing

from the cover to remove the speed gear.

6. Remove the clutch coil assembly and the oil seal

from the cover.

7. Remove the speed sensor and the O-ring from

the case cover.

TRANSFER CASE (PART TIME - 4408)  5D2-27

SSANGYONG  MY2002

KAA5D460

KAA5D470

Transfer Case Assembly

1. Separate the shift motor shaft cam assembly and

the spring (1).

KAA5D480

KAA5D490

2. Remove the clutch housing assembly from the

output shaft.

•

Clutch Housing Component

(1) Retaining Ring

(2) Shift collar Hub

(3) Clutch Housing

•

Remove the shift cam from the shaft.

•

Fix the shaft at the vise with the cam removed
and remove the torsion bar using a driver.

3. Remove the 2WD/4WD lock up assembly, the lock

up fork and rail shaft from the output shaft.