SsangYong Musso. Manual — part 509
5D1-20 TRANSFER CASE (PART TIME 4408)
<Adapter, Input Shaft and Carrier Gear>
72 Breather
73 Bolt
74 Adapter Assembly
75 Snap Ring
76 Oil Seal
77 Spiral Pin
78 Front Adapter
79 Retaining Ring
80 Bearing
81 Input Shaft Assembly
1. Remove the breather.
2. After removing 6 bolts, remove the front adopter by
separating the adapter sealer bond from the case
using a screw driver.
Notice
Be careful not to damage the contacting surface of
the case and adapter.
3. Remove the adapter assembly, input shaft assembly
and carrier gear assembly.
4. Remove the snap ring and oil seal from the front
adapter.
5. After removing snap ring, pull out the bearing and
thrust washer from the input shaft assembly and
separate the input shaft assembly from the carrier
gear assembly.
6. Remove the needle bearing and sleeve bearing from
the input shaft assembly.
7. Remove the retaining ring, thrust plate rind sun gear
from the planet carrier assembly.
Notice
Do not disassemble the planet carrier assembly.
82 Sleeve Bearing
83 Needle Bearing
84 Input Shaft
85 Thrust Bearing
86 Carrier Gear Assembly
87 Retaining Ring
88 Thrust Plate
89 Sun Gear
90 Planet Carrier Assembly
111 Case
TRANSFER CASE (PART TIME 4408) 5D1-21
<Electric Shifts Cam Parts>
1. Remove the electric shift cam parts from the case assembly.
2. Separate the electric shift cam from the shift shaft.
3. Holding the shift shaft in a vise, remove the torsion spring
and spacer from the shift shaft using a screw driver.
100
Electric Shift Cam
101
Torsion Spring
102
Spacer
103
Shift Shaft
111
Case
105
Transfer Case Assembly
106
Oil Seal
107
Retaining Ring
108
Ball Bearing
119
Pin
110
Ring Gear
111
Case
<Case Assembly>
1. Remove the oil seal.
2. Remove the retaining ring and bearing.
3. Remove the pin from the transfer case.
Notice
Be careful not to damage the pin.
4. Using a press, remove the ring gear from the case.
5D1-22 TRANSFER CASE (PART TIME 4408)
Cleaning Procedure
Notice
Before cleaning, check the magnet for the
presence of metal particles which indicate internal
chipping of the transfer case.
1. Using cleaning solvent, clean the residual oil and dirt
deposits.
Notice
During cleaning, be careful not to damage the metal
surfaces.
2. After cleaning, dry the parts with low pressure (Max. 20 psi)
compressed air.
3. Lubricate the ball bearings and needle bearings with transfer
case oil after cleaning.
Notice
Protect the lubricated bearings from dust.
Inspection Procedure
1. Visually check the all removed parts.
Notice
Always replace the hose coupling, O-ring and oil seal with
new parts.
2. Inspection Terms
!
Burr : Local rise of material forming protruding sharp
edge
!
Chip : An area from which a small fragment has been
broken off or cut
!
Crack : Surface break of line nature indicating partial or
complete separation of material.
!
Excessive wear : Heavy or obvious wear beyond
expectations considering conditions of operation.
!
Indentation : Displacement of material caused by localized
heavy contact.
!
Galling : Breakdown of metal surface due to excessive
friction between parts. Particles of the softer material
are torn loose and welded to the harder material.
!
Nick : Local break or notch, usually displacement of
material rather than loss.
!
Scoring : Tear or break in metal surface from contact
under abnormal pressure.
!
Step wear : Heavy wear that produces a step that can
be seen or felt between adjacent contact and noncontact
surfaces.
!
Uneven wear : Condition of localized, unevenly distributed
wear Includes hollows, shiny spots, uneven polish and
other visual indications.
TRANSFER CASE (PART TIME 4408) 5D1-23
3. Specific Inspection
!
Referring to normal gear tooth face, specifically inspect
the uneven wear and chips of gear tooth.
Replace or repair if necessary.
4. Inspection of Contact Patterns
Description
Normal
Abnormal
Normal Wear
End Face Wear
Traveling Face Wear
Upper Face Wear
Lower Face Wear
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