SsangYong Korando II (1996-2006 year). Manual — part 356
TRANSFER CASE (PART TIME - 4408) 5D2-23
SSANGYONG MY2002
KAA5D300
KAA5D310
KAA5D320
7. Support the transfer case with jack and remove
the front and rear propeller shafts from the transfer
case.
Installation Notice
81 - 89 N•m
(60 - 66 lb-ft)
70 - 90 N•m
(52 - 66 lb-ft)
Tightening
Torque
Front
Rear
12 - 23 N•m
(9 - 17 lb-ft)
6 - 8 N•m
(53 - 71 lb-in)
Tightening Torque(1)
Tightening Torque(2)
Tightening Torque
35 - 60 N•m
(26 - 44 lb-ft)
8. Remove the center mounting nuts and end sides
mounting bolts of the cross member and then
remove the cross member.
Installation Notice
9. Remove the transfer case by removing the bolts
attaching the transfer case to the transmission.
Installation Notice
Notice: Apply long-term grease to the inner spline
of the transfer case input shaft.
10. Installation should follow the removal procedure
in the reverse order.
TRANSFER CASE (PART TIME - 4408) 5D2-25
SSANGYONG MY2002
KAA5D380
KAA5D390
UNIT REPAIR
DISASSEMBLY PROCEDURE
Shift Motor Assembly
1. Separate the harness bracket.
2. Remove the shift motor mounting bolt and remove
the shift motor assembly.
KAA5D400
KAA5D410
Companion Flange
1. Holding the companion flange, remove the nut and
washer and then remove the companion flange.
2. Remove the oil seal.
3. Remove the companion flange from the case
cover.
Case Cover Assembly
1. Remove the cover mounting bolts(9), and the case
mounting bolts(5).
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.
SSANGYONG MY2002
5D2-26 TRANSFER CASE (PART TIME - 4408)
KAA5D420
KAA5D430
3. Remove the clutch coil wiring from the connector.
4. Remove the clutch coil assembly mounting nut.
KAA5D440
KAA5D450
5. Remove the snap ring and pull out the ball bearing
from the cover to remove the speed gear.
6. Remove the clutch coil assembly and the oil seal
from the cover.
7. Remove the speed sensor and the O-ring from
the case cover.
TRANSFER CASE (PART TIME - 4408) 5D2-27
SSANGYONG MY2002
KAA5D460
KAA5D470
Transfer Case Assembly
1. Separate the shift motor shaft cam assembly and
the spring (1).
KAA5D480
KAA5D490
2. Remove the clutch housing assembly from the
output shaft.
•
Clutch Housing Component
(1) Retaining Ring
(2) Shift collar Hub
(3) Clutch Housing
•
Remove the shift cam from the shaft.
•
Fix the shaft at the vise with the cam removed
and remove the torsion bar using a driver.
3. Remove the 2WD/4WD lock up assembly, the lock
up fork and rail shaft from the output shaft.
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