SsangYong Stavic / SsangYong Rodius (2005 year). Service 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.
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