2003 SSANGYONG MUSSO drive shaft

5B-40 MANUAL TRANSMISSION
INSPECTION OF COMPONENTS Inspection Procedure
1. Clean all parts with solvent and dry them with compressedair. Check the following parts for cracks and damaged sealing surfaces.
Case
Extension housing
Shift Cover
Input bearing retainer
Counter shaft rear bearing retainer
2. Check the parts which support bearings and shafts for excessive wear and replace them if necessary.
3. Check the bearing surfaces of the following parts ; Input shaft
Main shaft and its gears
Counter shaft and 5th drive gear
4. Check the reverse idler shaft and its gears. NoticeReplace excessive wear parts and do not file on the hardened surface and precision ground.

TRANSFER CASE (PART TIME 4408) 5D1-15
1 Nut
2 Spring Washer
3 Oil Seal
4 Companion Flange
5 Snap Ring
6 Torsional Damper
7 Pipe Plug
8 Bolt
9 Bolt
10 Speed Sensor and Harness
Bracket
11 Speed Sensor Assembly
12 Speed Sensor
13 O-Ring
14 Locking Clip
15 Connector
16 Motor Assembly
17 Oil Seal
18 Bearing
19 Bolt
20 Tag
21 Decal
22 Wiring Harness Clip
23 Bolt
24 Cover Assembly
25 Nut
26 Snap Ring
27 Bearing
28 Needle Bearing
29 Cover
30 Clutch Coil Assembly
31 Speed Gear
32 Oil Seal
33 Return Spring
34 Magnet
35 Clutch Housing 36 Lock-up Assembly
37 Snap Ring
38 Lock-up Hub
39 Sleeve Return Spring
40 Lock-up Collar
41 Rail Shaft
42 Lock-up Fork
43 Snap ring
44 Spacer
45 Driven Sprocket
46 Driven Sprocket
47 Drive Chain
48 Shaft and Pump Assembly
49 Screw
50 Pump Housing
51 Pump Gear Set
52 Pump Cover
53 Spring Pin
54 Hose Clamp
55 Hose Coupling
56 Oil Strainer
57 Output Shaft
58 Reduction Hub
59 Shift Fork Assembly
60 Shift Fork Facing
61 Pin, Roller and Retainer
62 Pin
63 Cam Roller
64 Retainer
65 Reduction Shift Fork
66 Nut
67 Plane Washer
68 Oil Seal
70 Companion Flange
71 Spacer
72 Front Output Assembly 73 Breather Hose
74 Bolt
75 Front Adapter Assembly
76 Snap Ring
77 Oil Seal
78 Spiral Pin
79 Front Adapter
80 Snap Ring
81 Bearing
82 Input Shaft Assembly
83 Sleeve Assembly
84 Needle Bearing
85 Input Shaft
86 Thrust Washer
87 Retaining Ring
88 Thrust Plate
89 Sun Gear
90 Gear Carrier Assembly
91 Planet Carrier
92 Pinion Shaft
93 Thrust Washer
94 Pinion Gear
95 Needle Roller Bearing
96 Pinion Needle Spacer
97 Electric Shift Cam
98 Torsion Spring
99 Spacer
100 Shift Shaft
101 Case Assembly
102 Oil Seal
103 Snap Ring
104 Bearing
105 Dowel Pin
106 Ring Gear
107 Case

TRANSFER CASE (PART TIME 4408) 5D1-17
1. Remove the 9 bolts, wiring harness clip andidentification 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.

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)

1. Remove the retaining ring and clutch housing from the shiftcollar 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)

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.

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

5D1-20 TRANSFER CASE (PART TIME 4408)

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. NoticeBe 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 andseparate 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

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 springand 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

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.

5D1-26 TRANSFER CASE (PART TIME 4408)
101 Torsion Spring
102 Spacer
103 Shift Shaft
3. Slide the torsion spring and spacer to the left of the shift
shaft and position the end of the first spring to fix on the drive tang.
4. Push the end of the second spring to right and fix it on thedrive tang.
101 Torsion Spring
102 Spacer
103 Shift Shaft
5. Push the torsion spring and spacer together back them completely.
6. Slide the electric shift cam onto the shift shaft.
7. Install the electric shift cam assembly into the transfer case after installation of the shift fork.
101 Torsion spring
102 Spacer
103 Shift Shaft

5D1-30 TRANSFER CASE (PART TIME 4408)
Oil Pump
1. Install the pump front cover to be the ‘TOP ’ mark down and
turn the cover to be the ‘TOP ’ mark up when installed in
vehicle.
2. Install the 2 pump pins and spring to the output shaft. NoticeFlat surface of the pins must point out and align the center
line of pins and spring.
3. Connect the hose coupling to the strainer coupling and install the strainer foot into the transfer case slot. Notice
The hose coupling must face the pump assembly.
4. Install the pump housing to be the 'REAR' mark up and seat the 2 pump pins inside of the pump housing by moving pump pins inward and compressing the spring.
5. Tighten the hose to pump housing by hose clamp.
6. Position the pump rear cover to be the ‘TOP REAR ’ mark
up and located at the top of transfer case when installed in
vehicle. Position the pump retainer on the cover so that tab
on the retainer is in notch in the transfer case. Apply Loctite
to the bolts and tighten the bolts with turning the output
shaft by hand to make the pump pins move freely. 45 Shaft and Pump Assembly
46 Bolt
47 Pump Retainer
48 Rear Pump Cover
49 Hose Clamp
50 Hose Coupling
54 Pump Housing
52 Pump Pin
53 Spring
54 Front Pump Cover
55 Output Shaft
56 Strainer
40 Snap Ring
41 Spacer
42 Drive Sprocket
43 Driven Sprocket
44 Drive Chain
55 Output Shaft (Rear)
71 Output Shaft (Front)
Drive Chain
1. Position the drive sprocket to the rear output shaft end and
driven sprocket to the front output shaft end.
2. Install the drive chain onto the sprocket.
3. Holding each sprocket to be the drive chain tight and parallel with transfer case, install the drive chain assembly to the output shafts.
4. Rotate the driven sprocket slightly to engage splines on the front output shaft.
5. Install the spacer to the front output shaft and insert the snap ring into the shaft groove over spacer.
Tightening Torque 4 - 8.5 Nm