2003 SSANGYONG MUSSO Service Manual

TRANSFER CASE (PART TIME 4408) 5D1-29
Front Output Shaft
1. Position the output shaft in transfer case and install thecompanion flange assembly, oil seal, washer and nut.
2. Holding the companion flange, tighten the nut.
65 Nut
66 Washer
67 Oil Seal
70 Companion Flange
71 Output Shaft (Front)
111 Case
55 Output Shaft
57 Reduction Hub
58 Shift Fork Facing
59 Reduction Shift Fork Assembly
60 Roller, Pin and Retainer Assembly
61 Retainer
62 Pin
63 Roller Cam
64 Reduction Shift Fork
Reduction Shift Parts
1. Install the new pin, roller and retainer into the reduction
shift fork.
2. Press the pin, roller and retainer into the reduction spilt fork bore completely.Notice
Make sure that the cam roller turns freely.
3. Install the 2 fork facing on the reduction shift fork assembly.
4. Install the reduction shift fork onto the previously installed reduction hub in the transfer case.
5. Install the output shaft spline into the reduction hub and engage the output shaft end with input shaft bearing. NoticeFor installation of the output shaft, assemble
the oil pump temporarily.

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

TRANSFER CASE (PART TIME 4408) 5D1-31
Lockup Shift
1. Install the lockup hub and return spring to the lockup collarand 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.
Rotate the shift cam assembly to right so that the end of
the torsion spring contacts with reduction shift fork side.
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.
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 markup 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. Install the 4 O-rings on the stud bolts of the clutch coil
assembly.
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
2 5 Cover
Tightening Torque 8 - 11 Nm
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 : Align the cover bores with transfer case pins.
Align the cover bearings with output shafts.
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
2 6 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 motorassembly 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
2 5 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

TRANSFER CASE (PART TIME 4408) 5D1-35
Companion Flange
1. Install the 2 plugs to the cover.
2. Install the companion flange, oil seal and washer.
3. Holding the companion flange, tighten the nut.1 Nut
2 Washer
3 Oil Seal
4 Companion Flange
5 Plug
2 5 Cover
Notice Apply Loctite 262 to nut before installation.
Tightening Torque 346 - 380 Nm

5D1-36 TRANSFER CASE (PART TIME 4408)
TRANSFER CASE CONTROL UNIT (TCCU) System Description TCCU is located under the front left handed seat and permits the vehicle to shift from two-wheel drive to four-wheel drive
(and back shift) according to driver ’s switch operation during
driving (For the shifting between 4WD HIGH and 4WD LOW, stop the vehicle).
1. Shifting from 2H to 4H
Position the transfer case switch from '2H' to '4H'.
Shifting is possible during driving.
'4WD Hl' indicator light will turn on.
2. Shifting from 4H to 2H Position the transfer case switch from '4H' to '2H'.
Shifting is possible during driving.
'4WD Hl' indicator light will turn off.
3. Shifting between 4H and 4L Shifting is possible when the vehicle is almost stopped
(below approx. 2 km/h), so it would be better stop the vehicle.
In case of manual transmission equipped vehicle, apply
clutch pedal.
In case of auto transmission equipped vehicle, put the
lever position into 'N'.
Position the transfer case switch '4H' to '4L' or '4L' to
'4H'.
According to the shifted position, indicator light will turn
on.
Notice
If there are malfunctions during shifting,'4H' or '4L' indicator light will blink.