SsangYong Stavic / SsangYong Rodius (2005 year). Manual - part 358

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

39

TOD

STAVIC - 2004.09

4D

1. Snap ring

2. Snap ring

3. Snap ring

4. Bearing

5. Hub

6. Input shaft assembly

7. Thrust plate

8. Sun gear

9. Snap ring

10. Carrier assembly

11. Reduction hub

12. Main shaft assembly

13. Geroter pump assembly

14. Thrust washer

15. Hose clamp

16. Hop

17. Filter

18. Electric coil assembly

19. Cam/coil housing assembly

20. Ball

21. Cam

22. Spring

23. Armature

24. Insulator washer

25. Retaining ring

26. Clutch pack assembly

27*. Sprocket  assembly

28. Shift rail

29. Shift fork assembly

30. Electric shift cam

31. Torsion spring

32. Shift shaft

33. Retaining ring

34*. Transfer case assembly

35. Breather

37. Output shaft

38. Dust shield

39. Magnet

40. Snap ring

41. Lower sprocket

42. Tone wheel (lower)

43. Chain

44. Thrust bearing assembly

45. Retaining ring

46. Bearing

47. Bearing

48. Cover

49. Clip

50. Bolt

51. Oil seal

52. Washer

53. Nut

54. Companion flange

55. Oil seal

56. Spacer

57. Tone wheel (upper)

58. Nut

59. “J” clip

60. Hexagon bolt

61. Clip

62. Connector

63. Connector lock

64. Hexagon cap screw

65. Speed sensor (upper)

66. Electric motor assembly

67. Oil seal

68. Pipe plug

69. Speed sensor (lower)

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

40

TOD

STAVIC - 2004.09

4D

03E-019

2. DISASSEMBLY PROCEDURE

1. Disconnect transfer case from vehicle

2. Using a 30 mm thin-wall socket, first remove the rear

output nut, output shaft yoke washer, oil seal then the
case flange.

3. Disconnect shift motor/clutch coil connector and speed

sensor connector from upper bracket of transfer case.

7. Remove shift motor.

6. Disconnect pin of clutch coil wire (yellow) from speed

sensor connector (7 pin) using long-nose plier.

4. Remove outer tube on speed sensor connector.

5. Remove wire supporting cape back side of speed sensor

connector.

 [Notice]

When disconnect connector, pull forwards grasping
connector housing.

 [Notice]

When remove shift motor, pay attention to the location of
triangular slot and shaft in transfer case inside motor.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

41

TOD

STAVIC - 2004.09

4D

8. Disconnect front and rear speed sensor as needed.

9. Remove the 17 bolts that retain the front case to the rear

case.

17. Remove the three nuts and washers retaining the clutch

coil assembly to the rear case.

18. Pull the assembly, along with the O-ring and wire, from

the case.

10. Make sure that the front case is facing downward so

that the rear cover is facing upwards.

11. Remove the rear front case from the rear case.

12. Remove all traces of gasket sealant from the mating

surfaces of the front case and rear case.

13. If the speedometer drive gear is to be replaced, first

remove the flange seal by prying and pulling the curved-
up lip of the flange seal.

14. Remove the speedometer drive gear and upper tone wheel.

15. If the rear output shaft bearing requires replacing, remove

the internal snap ring that retains the bearing in the bore.

16. From the outside of the case, drive out the bearing using

the driver.

 [Notice]

Be careful not to damage the bearing, bearing cage or case.
Remove and discard the flange seal.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

42

TOD

STAVIC - 2004.09

4D

19. Remove bearing assembly from output shaft.

20. Remove the clutch housing from the output shaft.

26. Remove the magnet from the slot in the front of the case

bottom.

27. Remove the output shaft and oil pump as an assembly.

28. If required, to remove the pump from the output shaft,

rotate the pump to align.

29. Pull out the shift rail.

30. Remove the helical cam from the front case.

31. If required, remove the helical cam, torsion spring and

sleeve from the shaft.

24. Remove the chain, driven sprocket and drive sprocket as

an assembly.

25. Remove thrust washer from output shaft.

21. Remove the balls and apply cam and wave washer from

the output shaft.

22. Remove snap ring from output shaft.

23. Remove clutch pack assembly from output shaft.