SsangYong Korando II (1996-2006 year). Manual - part 359

TRANSFER CASE (PART TIME - 4408)  5D2-35

SSANGYONG  MY2002

KAA5D750

KAA5D760

KAA5D770

ASSEMBLY PROCEDURE

•

Use special tools during assembly of oil seals and
bearings.

•

Lubricate bearings, oil seals and bushings before
assembly.

Transfer Case Assembly

1. If the ring gear was removed, align the outer

diameter of the new replaced ring gear with transfer
case and assemble it.

2. Insert the pin.

3. Insert the ball bearing to the case and install the

retaining ring.

4. Install the new oil seal by pressing into the case.

5. Make sure that all parts are correctly and firmly

installed into the case.

Electric Shift Cam Parts

1. Insert the spacer into torsion spring.

2. Insert the end of the shift shaft into the spacer

smoothly.

SSANGYONG  MY2002

5D2-36  TRANSFER CASE (PART TIME - 4408)

KAA5D780

KAA5D790

KAA5D800

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.

5. Push the torsion spring and spacer together back

them completely.

6. Slide 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.

TRANSFER CASE (PART TIME - 4408)  5D2-37

SSANGYONG  MY2002

KAA5D810

KAA5D820

Adapter, Input Shaft and Carrier

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.

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.

Installation Notice

Tightening Torque

28 - 40 N•m

(21 - 30 lb-ft)

4 - 7 N•m

(35 - 62 lb-in)

Item

6 Bolts

Breather

Front Output Shaft

Cross Sectional View

SSANGYONG  MY2002

5D2-38  TRANSFER CASE (PART TIME - 4408)

KAA5D830

KAA5D840

KAA5D850

Input Shaft

Cross Sectional View

Tightening Torque

346 - 380 N•m

Front Output Shaft

1. Install the deflector on the 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.

Installation Notice

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.