2003 SSANGYONG MUSSO electric

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

5D1-16 TRANSFER CASE (PART TIME 4408)
Disassembly Procedure
1. Holding the companion flange, remove the nut and washerand then remove the companion flange and oil seal.
2. Remove the 2 plugs from the cover.
1 Nut
2 Washer
3 Oil Seal
4 Companion Flange
5 Plug
2 5 Cover
6 Bolt
7 Washer
8 Bolt
9 Sensor and Harness Bracket
10 Sensor Assembly 11 Speed Sensor
12 O-ring
13 Motor Assembly
2 5 Cover

1. Remove the bolt, washer,3 bolts and harness bracket.
2. Remove the sensor assembly and remove the O-ring from
the speed sensor.
3. Remove the motor assembly.

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

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.

TRANSFER CASE (PART TIME 4408) 5D1-25
Electric Shift Cam Parts
1. Insert the spacer into torsion spring.
2. Insert the end of the shift shaft into the spacer smoothly.100 Electric Shift Cam
101 Torsion Spring
102 Spacer
103 Shift Shaft
Assembly Procedure General Information
1. Use special tools during assembly of oil seals and bearings.
2. Lubricate bearings, oil seals and bushings before assembly.105 Case Assembly
106 Oil Seal
107 Retaining Ring
108 Ball Bearing
109 Pin
110 Ring Gear
111 Case
106 Oil Seal
109 Pin
110 Ring Gear
111 Case
Transfer Case
1. If the ring gear was removed, align the outer diameter of
the new replaced ring gear with transfer case and assemble it.
2. Insert the pin.
3. Insert the ball bearing to the case and install the retaining ring.
4. Install the new oil seal by pressing into the case.
5. Make sure that all parts are correctly and firmly installed into 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

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

5D1-34 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