1997 SSANGYONG KORANDO transfer case

SSANGYONG MY2002
5D1-68 TRANSFER CASE
KAA5D280
KAA5D290
KAA5D300
KAA5D310
8. Disconnect breather hose on the front upper side
of the transfer case near front propeller shaft.
12. Remove five bolts that connect transfer case and
transmission adapter housing.
Installation Notice 11. Remove 4 bolts that connecting the rear propeller
shaft and rear output shaft flange.
Installation Notice 9. Prepare a hydraulic jack and support the transfer
case assembly.
10. Remove 4 bolts that connecting the front propeller
shaft and front output shaft/flange.
Installation Notice
Make sure the connecting surface is clean.
Apply long life grease inside transfer case input
shaft.
13. Installation should follow the removal procedure
in the reverse order.
Tightening Torque81 - 89 Nm
(60 - 66 lb-ft)
Tightening Torque81 - 89 Nm
(60 - 66 lb-ft)
Tightening Torque38 - 52 Nm
(28 - 38 lb-ft)

TRANSFER CASE 5D1-69
SSANGYONG MY2002
KAA5D320
KAA5D330
SHIFT MOTOR
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect shift motor and clutch coil connector
(black 7 pin) on upper backside of transfer case.
3. Remove three shift motor mounting bolts.
Installation Notice
6. Keeps the shift motor even and pull out carefully.
Notice: When removing shift motor, pay attention
to the location of triangular slot and shaft in
transfer case inside motor and mark the position.
7. Installation should follow the removal procedure
in the reverse order.
Installation Notice:
Clean the connection surface between transfer
case and shift motor.
Apply black non-acid cure silicone rubber or
equivalent to the surface.
Do not disassemble the shift motor and replace
with new one, if necessary.
Make sure the motor position to match with 4H/
4L switch selection. 4. Remove one shift motor bracket bolt.
Installation Notice
5. Loose two adjusting bolts on the shift motor if
neces-sary.
Installation Notice
Tightening Torque8 - 11 Nm
(70 - 97 lb-in)
Tightening Torque8 - 11 Nm
(70 - 97 lb-in)
Tightening Torque3 - 5 Nm
(27 - 44 lb-in)

SSANGYONG MY2002
5D1-70 TRANSFER CASE
KAA5D340
KAA5D350
FRONT AND REAR PROPELLER
SHAFT SPEED SENSOR
Removal and Installation Procedure
1. Disconnect negative battery cable.
2. Disconnect front and rear speed sensor connector
(white 7 pin).
3. Remove shift motor. Refer to “Shift Motor” in this
sec-tion.
4. Remove front and rear propeller shaft speed
sensor retaining bolts.
Installation Notice
6. Disassemble the connector of front and rear
propeller shaft speed sensor.
7. Replace front or rear propeller shaft speed sensor,
as necessary.
Notice:
While replacing the speed sensor, make sure
the proper pin position.
Do not remove one wire to clutch coil in the
transfer case.
Make tidy on the wiring harness including
conduct tube.
8. Installation should follow the removal procedure
in the reverse order. 5. Remove the speed sensors by lifting up using
a tool such as flat screw drive.
Notice: Do not shock the speed sensor because
it is too sensitive at shock.
Tightening Torque3 - 6 Nm
(27 - 53 lb-in)

TRANSFER CASE 5D1-71
SSANGYONG MY2002
KAA5D360
KAA5D330
KAA5D380
UNIT REPAIR
TRANSFER CASE OVERHAUL
Disassembly Procedure
1. Remove the transfer case assembly. Refer to
“Transfer Case” in this section.
2. Disassemble the white 7 pin connector of propeller
shaft speed sensor and separate the pin
connected to brown wire to clutch coil.
3. Remove the propeller shaft speed sensors with
wires. Refer to “Front and Rear Propeller Shaft
Speed Sensor” in this section.
4. Remove vehicle speed sensor. Refer to Section
1F, Engine Control.
7. Remove the bolts that retain the front case to the
rear cover.
Notice:
Make sure that the front case is facing
downward so that the rear cover is facing
upwards.
Pry on the bosses and separate the front case
from the rear cover.
Remove all traces of gasket sealant from the
mating surfaces of the front case and rear cover. 5. Remove shift motor/clutch coil. Refer to “Shift
Motor and Clutch Coil” in this section.
Notice: When removing shift motor, pay attention
to the location of triangular slot and shaft in
transfer case inside motor and mark the position.
6. Using a 30 mm thin-wall socket, first remove the
rear output shaft nut, rear output shaft yoke
washer, oil seal then the rear output shaft flange.

SSANGYONG MY2002
5D1-72 TRANSFER CASE
KAA5D390
KAA5D400
KAA5D410
KAA5D420
8. Remove the rear output shaft oil seal and discard
it, if required.
9. Remove the speedometer drive gear and rear pro-
peller shaft speed sensor tooth wheel.
10. Remove the internal snap ring that retains the rear
output shaft bearing in the bore.
Notice: Push the bearing from the outside of the
case.
14. Remove the balls, apply cam and wave washer
from the output shaft.
15. Remove snap ring from output shaft.
16. Remove clutch pack assembly from output shaft. 12. Remove thrust bearing from the rear output shaft.
13. Remove the clutch coil housing from the rear
output shaft. 11. Remove three nuts retaining the clutch coil assem-
bly and pull the clutch coil assembly along with
the wire from the case.

TRANSFER CASE 5D1-73
SSANGYONG MY2002
KAA5D430
KAA5D440
KAA5D450
KAA5D460
17. Remove the front propeller shaft speed sensor
tooth wheel.
18. Remove the chain, driven sprocket and drive
sprocket as an assembly.
19. Remove thrust washer from output shaft.
25. With expanding the tangs of the snap ring under
the planetary carrier assembly using SST snap ring
plier support the input shaft against a bench, push
the case down and slide the input shaft bearing.
Remove the input shaft and planetary carrier.
26. Remove and discard the input shaft oil seal as re
quired.
27. Remove the internal snap ring from the planetary
carrier and separate the planetary carrier from the
input shaft. 22. Remove the helical cam and shift rail as an assem-
bly by gently pulling out the shift rail. Check the
helical cam for damages and replace it if required.
23. Remove the high-low shift fork and high-low collar
as an assembly.
24. Remove the shift shaft. 20. Remove the magnet from the slot in the front of
the case bottom.
21. Remove the rear output shaft and oil pump as an
as-sembly.
Notice: If there is removal resistance, do not
pound or use force to disassemble the pump. Do
not disassemble oil pump. It is serviced only as
an assembly. Check the pump to make sure the
pump rotates freely.

SSANGYONG MY2002
5D1-74 TRANSFER CASE
KAA5D470
KAA5D480
KAA5D490
KAA5D500
28. Remove the external snap ring from the input shaft.
29. Place the input shaft in a vise and remove the
bear ing.
30. Remove the thrust washer, thrust plate and the
sun gear off the input shaft.
Assembly Procedure
Important: Lubricate all parts with automatic transmis-
sion fluid (ATF) or equivalent before assemble. Remove
all traces of gasket sealant from the front case and
mounting adapter mating surfaces
1. Install the front output shaft bearing, if removed.
Notice: Press the bearing in straight, making sure
it is not cocked in the bore.
2. Install the internal snap ring that retains the front
output shaft bearing. 33. Remove the external snap ring retaining the front
output shaft.
34. Remove the front output shaft/flange.
35. Remove and discard front output shaft oil seal,
as required.
36. Remove the internal snap ring and remove the front
output shaft bearing, as required. 31. Position the input shaft on SST input shaft support.
32. Remove the needle bearing and bushing using
SST bearing installer/remover, as required.
Notice: Under normal use, the needle bearing and
bushing may not require replacement. After
inspection, If replacement is required, the bushing
and needle bearing must be replaced as a set.

TRANSFER CASE 5D1-75
SSANGYONG MY2002
KAA5D510
KAA5D520
KAA5D460
3. Install the front output shaft oil seal using oil seal
installer, if removed.
4. Install the front output shaft/flange and install the
snap ring.
8. Assemble the planetary carrier to the sun gear and
input shaft and install the internal snap ring to the
planetary carrier.
9. While expanding the tanged snap ring with SST
snap ring pliers install planetary carrier assembly.
10. Install the high-low shift fork and collar as an
assembly.
Notice: Make sure that the nylon wear pads are
installed on the shift fork and snapped securely
into place. 6. Slide the sun gear, thrust plate and thrust washer
into position on the input shaft.
Notice: The recessed face of the sun gear and
the snap ring groove on the bearing outer race
should be toward the rear of the transfer case.
The stepped face of the thrust washer should face
toward the bearing.
7. Install the bearing over the input shaft using input
shaft bearing installer SST. Install the external snap
ring. 5. Install a new input shaft needle bearing and a new
bushing, if removed. Keep the following steps to
install the bearing and the bushing:
Position the input shaft on input shaft support.
Press a new needle bearing into the end of the
input shaft until it seats in the input shaft using
bearing remover/installer.
Press in a new bushing.