SsangYong Musso. Service manual — part 508
5D1-16 TRANSFER CASE (PART TIME 4408)
Disassembly Procedure
<Companion Flange>
1. Holding the companion flange, remove the nut and washer
and then remove the companion flange and oil seal.
2. Remove the 2 plugs from the cover.
1 Nut
2 Washer
3 Oil Seal
4 Companion Flange
5 Plug
25 Cover
6 Bolt
7 Washer
8 Bolt
9 Sensor and Harness Bracket
10 Sensor Assembly
11 Speed Sensor
12 O-ring
13 Motor Assembly
25 Cover
<Extension Electric Shift>
1. Remove the bolt, washer,3 bolts and harness bracket.
2. Remove the sensor assembly and remove the O-ring from
the speed sensor.
3. Remove the motor assembly.
TRANSFER CASE (PART TIME 4408) 5D1-17
1. Remove the 9 bolts, wiring harness clip and
identification tag.
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.
3. Remove the oil seal, bearing, 3 nuts and clutch coil
assembly of the electric shift unit.
<Cover Assembly>
14 Bolt
15 Wiring Clip
16 Identification Tag
17 Cover Assembly
18 Oil Seal
19 Bearing
20 Nut
21 Clutch Coil Assembly
22 Snap Ring
23 Ball Bearing
4. Remove the snap ring and pull out the ball bearing
from the cover to remove the speed gear.
5. Pull out the needle bearing from the cover.
6. Pull out the oil seal from the slot in cover.
7. Remove the magnet form the slot in case.
8. Remove the return spring from the rail shaft.
9. Be careful not to damage the metal surface when
removing the sealant of the cover and case.
24 Needle Bearing
25 Cover
26 Magnet
27 Speed Gear
28 Oil Seal
29 Return Spring
38 Rail Shaft
55 Output Shaft
111 Transfer Case
5D1-18 TRANSFER CASE (PART TIME 4408)
<Lock-up Shift Parts>
1. Remove the retaining ring and clutch housing from the shift
collar hub.
2. Remove the shift collar hub from the output shaft.
3. Separate the 2WD - 4WD lock-up assembly and lock-up
fork from the output shaft and remove the rail shaft.
4. To remove the 2WD - 4WD lock-up assembly, separate the
return spring, lock-up hub and snap ring from the lock-up
collar.
30
Retaining Ring
31
Clutch Housing
32
Shift Collar Housing
33
2WD/4WD Lock-up Assembly
34
Snap Ring
35
Lock-up Hub
36
Return Spring
37
Lock-up Collar
38
Rail Shaft
39
Lock-up Fork
55
Output Shaft
40
Snap Ring
41
Spacer
42
Drive Sprocket
43
Driven Sprocket
44
Drive Chain
55
Output Shaft(Rear)
71
Output Shaft(Front)
<Drive Chains>
1. Remove the snap ring and spacer from the output shaft.
2. Remove the drive chain, driven sprocket and drive sprocket
from the output shaft.
3. Separate the chain and sprocket when removing the
assembly.
<Pump Parts>
1. Remove the 4 bolts and retainer and separate the output
shaft and rear pump cover.
2. Loosen the hose clamp and remove the hose coupling from
the pump housing.
3. Remove the hose clamp, hose coupling and strainer.
4. Remove 2 pump pins and spring from the output shaft.
5. Separate the front pump and remove the output shaft.
45
Shaft and Pump Assembly
46
Bolt
47
Pump Retainer
48
Rear Pump Cover
49
Hose Clamp
50
Hose Coupling
51
Pump Housing
52
Pump Pin
53
Spring
54
Front Pump Cover
55
Output Shaft
56
Strainer
TRANSFER CASE (PART TIME 4408) 5D1-19
<Front Output Assembly>
1. Holding the companion flange, remove the nut and washer
and then remove the companion flange and oil seal.
2. Remove the output shaft.
65 Nut
66 Washer
67 Oil Seal
70 Companion Flange
71 Output Shaft (front)
111 Case
57
Reduction Hub
58
Shift Fork Facing
59
Reduction Shift Fork Assembly
60
Roller Pin and Retainer Assembly
61
Retainer
62
Pin
63
Roller Cam
64
Reduction Shift Fork
<Reduction Shift Parts>
1. Remove the reduction hub and reduction shift fork assembly
from the case.
2. Remove the 2 shill fork facings from the shift fork assembly.
3. To remove the roller cam and pin, cut elf the plastic retainer
when disassembling the fork assembly.
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