Daewoo Musso. Manual — part 298
TRANSFER CASE (PART TIME 4408) 5D1-31
Lockup Shift
1. Install the lockup hub and return spring to the lockup collar
and insert the snap ring.
2. Install the rail shaft through reduction shift fork assembly
previously installed and into the blind hole in case.
3. Engage the lockup fork into the 2WD/4WD groove and
check operation.
4. Install the shift collar hub to the output shaft spline.
5. Install the previously assembled electric shift cam and
assemble the clutch housing as follows.
l
Rotate the shift cam assembly to right so that the end of
the torsion spring contacts with reduction shift fork side.
l
Holding the rail shaft, lift up the fork assembly slightly.
Adjust electric shift cam assembly so that the roller on
reduction shift fork assembly is in groove in shift cam
and button on lockup fork is on cam end.
l
Install the clutch housing over shift collar hub and insert
the retaining ring into the clutch collar hub groove.
30
Retaining Ring
31
Clutch Housing
32
Shift Collar Housing
33
2WD/4WD
Lockup Assembly
34
Snap Ring
38
Rail Shaft
39
Lockup Fork
59
Reduction Shift Fork Assembly
100
Electric Shift Cam
101
Torsion Spring
35
Lockup Hub
36
Return Spring
37
Lockup Collar
38
Rail Shaft
39
Lockup Fork
55
Output Shaft
5D1-32 TRANSFER CASE (PART TIME 4408)
Cover
1. Position the cover to be the open end up on the work table.
2. Position the end of needle bearing to be identification mark
up and press into the cover until upper end of bearing is
40.47 - 40.97mm below cover face that contacts with transfer
case.
3. Press the ball bearing into the cover and install the snap
ring .
4. Install remaining parts as follows.
l
Install the 4 O-rings on the stud bolts of the clutch coil
assembly.
l
Install the clutch coil assembly inside the cover and
tighten 3 nuts.
18
Oil Seal
19
Bushing
20
Nut
21
Clutch Coil Assembly
22
Snap Ring
23
Ball Bearing
24
Needle Bearing
25
Cover
Tightening Torque
8 - 11 Nm
l
Install the bearing and motor bearing into the cover.
TRANSFER CASE (PART TIME 4408) 5D1-33
4. Install the cover onto the transfer case as follows :
l
Align the cover bores with transfer case pins.
l
Align the cover bearings with output shafts.
l
Align the cover blind hole with rail shaft and make sure
that return spring is not cocked.
29
Return Spring
38
Rail Shaft
55
Output Shaft
71
Front Output Shaft
103
Shift Shaft
109
Dowel Pin
Cover Assembly
14
Bolt
15
Wiring Clip
16
Identification Tag
17
Cover Assembly
26
Magnet
27
Speed Gear
28
Oil Seal
29
Return Spring
38
Rail Shaft
111
Case
1. Install the return spring over rail shaft in the transfer case.
2. Insert the magnet into the transfer case slot.
3. Apply 1.6mm bead of Loctite RTV 598 to the transfer case
mounting surface.
Notice
For installation of cover, align the transfer case with cover
not to use excessive force.
13
Motor Assembly
14
Bolt
15
Wiring Clip
16
Identification Tag
5. Tighten 9 bolts positioning identification tag and wiring clip.
6. Install the speed gear over output shaft spline in the cover
assembly.
7. Press the new oil seal into the cover assembly.
Tightening Torque
28 - 48 Nm
5D1-34 TRANSFER CASE (PART TIME 4408)
External Electric Shift
1. Align the motor with shift shaft and position the motor
assembly onto the cover.
2. Install the motor to the shift shaft and contact cover androtate
the motor clockwise direction to check correctengagement.
6
Bolt
7
Washer
8
Bolt
9
Sensor and Harness Bracket
10
Sensor Assembly
14
Speed Sensor
12
O-ring
13
Motor Assembly
25
Cover
13
Motor Assembly
103
Shift Shaft
3. Insert the 0-ring on the speed sensor speed sensor
assembly to the cover.
4. Install the bracket to the motor assembly and tighten 3bolts.
Tightening Torque
8 -11 Nm
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