SsangYong Stavic / SsangYong Rodius (2005 year). Manual - part 359

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

43

TOD

STAVIC - 2004.09

4D

42. Inspect the bushing and needle bearing in the end of the

input shaft for wear or damage.

32. Remove the high-low range shift fork and collar as an

assembly.

33. Expand the tangs of the large snap ring in the case.

34. With the input shaft against a bench, push the case down

and slide the main drive gear bearing retainer off the
bearing.

35. Lift the input shaft and front planet from the case.

36. If required, remove the oil seal from the case by prying

and pulling on the curved-up lip of the oil seal.

40. Place the input shaft in a vise and remove the bearing.

41. Remove the thrust washer, thrust plate and the sun gear

off the input shaft.

37. Remove the internal snap ring from the planetary carrier.

38. Separate the front planet from the input shaft.

39. Remove the external snap ring from the input shaft.

 [Notice]

Be careful not to damage the bearing, bearing cage or case.

 [Notice]

Under normal use, the needle bearing and bushing should
not require replacement. If replacement is required, the
bushing and needle bearing must be replaced as a set.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

44

TOD

STAVIC - 2004.09

4D

44. If required, remove the front yoke to flange seal by prying

and pulling on the curved-up lip of the yoke to flange
seal.

43. If replacement of the needle bearing and bushing is

required, press the bearing and bushing is required, press
the bearing and bushing out as follows:

• Position the input shaft on Axle Bearing/Seal plate,

and using Pinion Bearing Cone Replacer as a spacer.

• Insert Input Shaft Bearing Remover into the input shaft

so it is resting on top of the bearing cage.

• Tighten the actuator pin until it stops, then press the

bearing and bushing out together.

 [Notice]

Be careful not to damage the bearing, bearing cage or case.

45. If required, remove the internal snap ring retaining the

front output shaft ball bearing and remove the bearing.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

45

TOD

STAVIC - 2004.09

4D

6. If the input shaft needle bearing and bushing were

removed, install a new bearing and bushing as detailed
in the following steps:

Press a new needle bearing, then a new bushing in the
input shaft as follows:

• Position the input shaft on Axle Bearing/Seal Plate

or equivalent, and Pinion  Bearing Cone Replacer as
a spacer.

• Press a new needle bearing into the end of the input

shaft until it seats in the input shaft.

• Press in a new bushing.

3. ASSEMBLY PROCEDURE

1. Before assembly, lubricate all parts with Automatic

Transmission Fluid or equivalent.

2. If removed, drive the bearing into the front output case

bore.

3. Install the internal snap ring that retains the bearing to

the front case.

4. If removed, install the front yoke to flange seal in the

front case bore.

5. If removed, install the yoke to flange seal into the mounting

adapter bore.

 [Notice]

Drive the bearing in straight, making sure it is not cocked in
the bore.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

46

TOD

STAVIC - 2004.09

4D

12. Install the front planet to the sun gear and input shaft.

13. Install the internal snap ring to the planetary carrier.

7. The recessed face of the sun gear and the snap ring

groove on the bearing outer race should be toward the
rear of the transfer case.

8. The stepped face of the thrust washer should face toward

the bearing.

9. Slide the sun gear, thrust plate and thrust washer into

position on the input shaft.

10. Press the bearing over the input shaft.

11. Install the external snap ring to the input shaft.

14. Place the tangled snap ring in the case. Expand snap

ring with snap ring pliers and install planetary carrier
assembly. Check installation by holding the case and
carefully tapping the face of the input shaft against a
wooden block to make sure the snap ring is installed.

15. Remove all traces of gasket sealant from the front case

and mounting adapter mating surfaces. Install a bead of
gasket sealant on the surface of the front case.

16. Install the high-low shift fork and high-low collar as an

assembly into the front planet.

17. If new pump is used, align the flat of the output shaft and

the flat of the pump. Slide the pump onto the output shaft.