SECTION 5D2

TRANSFER CASE (PART TIME - 4408)

TABLE OF CONTENTS
General Infromation and Operation .................. 5D2-2 Transfer Case Assembly .................................. 5D2-17
4WD Operation Overview ................................... 5D2-2 Disassembly and Assembly ............................ 5D2-18
System Structure ............................................... 5D2-3 Maintenance and Repair ................................. 5D2-20
2H Mode (Rear Wheel Drive) .............................. 5D2-5 On-Vehicle Service ............................................. 5D2-20
4H Mode (4WD Drive - High Speed) ................... 5D2-6 Maintenance of Transfer Case Lubricant ........... 5D2-20
4H Mode (4WD Drive - Low Speed) .................... 5D2-7 4H and 4L Indicator ......................................... 5D2-21
System Description ........................................... 5D2-8 TCCU Inspection ............................................. 5D2-21
Specifications .................................................... 5D2-9 Transfer Case Assembly .................................. 5D2-22
Diagnostic Infromation and Procedures .......... 5D2-10 TCCU .............................................................. 5D2-24
General Diagnosis ........................................... 5D2-10 Unit Repair ........................................................ 5D2-25
Self-Diagnosis Test .......................................... 5D2-11 Disassembly Procedure ................................... 5D2-25
Diagnostic Diagram ......................................... 5D2-15 Assembly Procedure ....................................... 5D2-35
Component Locator ......................................... 5D2-16
Cross Sectional View ....................................... 5D2-16
5D2-2 TRANSFER CASE (PART TIME - 4408)

GENERAL INFORMATION AND OPERATION

4WD OPERATION OVERVIEW
Application Mode Position Operation Condition
Driving Type 2H 2WD Drive (Rear • Normal Driving on the normal road or highway, or
Wheel Drive) high speed driving
4H 4WD Drive (High • Slipped road such as snow, rainy, sand, mud etc.
Speed)
4L 4WD Drive (Low • Max driving force requiring condition such as
Speed) towing, rough road.
• When a vehicle is driven in turning at low speed on
the paved road, a vibration and a noise may be
occurred by tight corner braking.
Transferring 2H ↔ 4H 2WD Drive ↔ 4WD • 2WD ↔ 4WD transfer is possible below 70 km
Drive (High Speed) without operating the clutch.
2H, 4H ↔ 4L 2WD Drive, 4WD • Manual Transmission
Drive (High Speed) Transfer starts after the vehicle stops and the clutch
↔ 4WD Drive (Low is applied
Speed) • Automatic Transmission
Transfer starts after the vehicle stops and the shift
lever is shifted [N] position.

Notice: After the vehicle stops and the mode switch

is selected with applying the brake pedal, shifting
[N-R-N] makes the mode transfer easier.

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 TRANSFER CASE (PART TIME - 4408) 5D2-3

SYSTEM STRUCTURE

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5D2-4 TRANSFER CASE (PART TIME - 4408)

Power Flow

Switch Transfer
2H, 4H ↔ 4L

TCCU

Locking Hub Solenoid

Vacuum System Operation

Locking Hub Transfer

Operation

Front Propeller Shaft

Rear Propeller Shaft

Front Axle Rear Axle

Front Wheel Rear Wheel

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 TRANSFER CASE (PART TIME - 4408) 5D2-5

2H MODE (REAR WHEEL DRIVE)

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Power Flow

Transmission Output
Shaft

T/C Input Shaft Rear Wheel

Output Shaft Rear Propeller Shaft Rear Axle

Rear Wheel

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5D2-6 TRANSFER CASE (PART TIME - 4408)

4H MODE (4WD DRIVE - HIGH SPEED)

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Power Flow

Transmission
TCCU Motor
Input Shaft

Shift Cam, Rail,

Fork

Magnetic
Clutch

Hub Output Shaft

Chain

Front Propeller Rear Propeller

Shaft Shaft

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 TRANSFER CASE (PART TIME - 4408) 5D2-7

4L MODE (4WD DRIVE - LOW SPEED)

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Power Flow

Transmission
TCCU Motor
Input Shaft

Shift Cam, Rail,

Fork

Hub

Planetary Gear
(2.483)

Chain Output Shaft

Front Propeller Rear Propeller

Shaft Shaft

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5D2-8 TRANSFER CASE (PART TIME - 4408)

SYSTEM DESCRIPTION
Transfer Case Control Unit (TCCU)
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 drivers
switch operation during driving (For the shifting
between 4WD HIGH and 4WD LOW, stop the vehicle).

KAA5D050

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.
KAA5D060

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.
KAA5D070
Notice: If there are malfunctions during shifting,
‘4H’ or ‘4L’ indicator light will blink.

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 TRANSFER CASE (PART TIME - 4408) 5D2-9

SPECIFICATIONS

Model Part-Time 4408 (E)

Type E.S.O.F. Type
Gear Ratio High 1:1
Low 2.48 : 1
Oil Specification ATF S-3, S-4 or DEXRON II, III
Capacity 1.2 L
Lubrication Check : Every 10,000 km
Replace : Every 60,000 km
Manufacturer Borg Warner
Weight 30 kg

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5D2-10 TRANSFER CASE (PART TIME - 4408)

DIAGNOSTIC INFORMATION AND PROCEDURES

GENERAL DIAGNOSIS
Symptoms Check Action
Electric shift problems • Faulty or damaged TCCU, speed • Overhaul and check, replace if neces-
sensor, motor, clutch or internal wirings sary.
• Damaged or worn shift cam, hub, fork • Overhaul and check for wear and
and rail shift damage.
• Binding shift fork, hub collar or gear • Replace if necessary.
Cannot front wheel • Broken drive chain • Check sliding parts, replace if neces-
drive when shifted 4H, sary.
4L
Noise in 4WD opera- • Improper or low oil • Drain and replace with specified oil.
tion • Loosened bolts or mounted parts • Retighten as specified.
• Noisy T/C bearing • Disassemble bearings and parts and
check for wear or damage. Replace if
necessary.
• Gear abnormal noise • Check for wear and damage including
speedometer gear, replace if neces-
sary.
Noise in 4H or 4L • Worn or damaged sprockets or drive • Disassemble and check for wear and
chain damage, replace if necessary.
• Incorrect tire pressure • Adjust tire pressure.
Transfer case oil • Cracked transfer case • Replace the case.
leakage • Leakage from other parts • Clean case and parts and check for
leakage.
• Breather clogging • Remove breather hose and clean,
replace if necessary.
• Improper or too much oil • Use specified oil and adjust oil level.
• Loosened sealing bolts • Retighten
• Improperly applied sealant • Use specified sealant and retighten.
• Worn or damaged oil seal • Replace

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 TRANSFER CASE (PART TIME - 4408) 5D2-11

SELF-DIAGNOSIS TEST
System Description
1. TCCU detects transfer case system malfunctions
and indicates malfunctioning part(s) through
flashing 4H, 4L indicator lights.
Using a service connector, connect it to the
diagnosis box in under instrument pannel and read
the flashing of the “4WD CHECK” indicator light.
The flashing indicator light will show you defective
code(s).
2. Identify 7 defective codes after reading the
KAA5D080 flashing indicator light.
• TCCU
• Shift motor
• Magnetic synchronizer clutch
• Speed sensor
• Hub solenoid
• Selector switch
• Motor position sensor

KAA5D090

3. Transfer case system is malfunctioning when:

• 4H, 4L indicator lights are remain on after 0.6
second when turning the ignition switch ON.
• 4H, 4L indicator lights are continuously come
on during driving.

KAA5D100

4. If only 1 part is malfunctioning, 4WD CHECK

indicator light will display defective code 3 times
continuously.
5. If more then 2 part is malfunctioning, the first
malfunctioning part will be displayed 3 times and
following malfunctioning parts will be displayed .
6. To read defective code, connect the service
connector and turn the ignition switch ‘ON’.
7. After repairing, eliminate the defective code stored
in the TCCU.
Notice: Before replacing the malfunction parts with
defective code, check the wires and connectors
KAA5D110
for proper condition.

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5D2-12 TRANSFER CASE (PART TIME - 4408)

Defective Code Reading

1. Position the ignition switch to OFF.
2. Using a service connector, connect the diagnosis
socket under instrument pannel.
3. Position the ignition switch to ON.
4. Read the flashing 4WD CHECK indicator light and
identify the malfunctioning part (See Diagnosis
Table).

KAA5D120

How to Clear the Fault Code

1. Position the ignition switch to OFF.
2. Using a service connector, connect the diagnosis
socket in under instrument pannel.
3. Position the ignition switch to ON over 5 seconds.
4. Do defective code reading and make sure that all
defective codes are eliminated.

KAA5D130

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 TRANSFER CASE (PART TIME - 4408) 5D2-13

Diagnostic Table
Connect a service connector. If turn the ignition switch
“ON” “4WD CHECK” indicator light will come on for
0.6 second and turn off for 3 seconds and then display
a defective code 3 times continuously.

No. Defective Code Malfunctioning Part

4WD CHECK
1 Light TCCU
ON
OFF

KAA5D140

4WD CHECK
2 Light Shift Motor
ON
OFF

KAA5D150

4WD CHECK
3 Light Synchronizer Clutch
ON
OFF

KAA5D160

4WD CHECK
4 Light Speed Sensor
ON
OFF

KAA5D170

4WD CHECK
5 Light Locking Hub Solenoid
ON
OFF

KAA5D180

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5D2-14 TRANSFER CASE (PART TIME - 4408)

No. Defective Code Malfunctioning Part

4WD CHECK
6 Light Selector Switch
ON
OFF

KAA5D190

4WD CHECK
7 Light Motor Position Sensor
ON
OFF

KAA5D200

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 TRANSFER CASE (PART TIME - 4408) 5D2-15

DIAGNOSTIC DIAGRAM

KAA5D210

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5D2-16 TRANSFER CASE (PART TIME - 4408)

COMTONENT LOCATOR
CROSS SECTIONAL VIEW

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KAA5D250

SSANGYONG MY2002
 TRANSFER CASE (PART TIME - 4408) 5D2-17

TRANSFER CASE ASSEMBLY

KAA5D260

1 Rear Companion Flange 8 Transmission Extension Housing

2 Case Cover 9 Bolt
3 Front Companion Flange 10 Washer
4 Breather Plug 11 Front Propeller Shaft
5 Transfer Case 12 Bolt
6 Input Shaft 13 Washer
7 Mounting Bolt 14 Rear Propeller Shaft

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5D2-18 TRANSFER CASE (PART TIME - 4408)

DISASSEMBLY AND ASSEMBLY

KAA5D370

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 TRANSFER CASE (PART TIME - 4408) 5D2-19

1 Transfer Case 41 Rail Shaft

2 Spring Washer 42 Lock-up Fork
3 Oil Seal 43 Snap ring
4 Companion Flange 44 Spacer
5 Shift shaft 45 Driven Sprocket
6 Oil Seal 46 Driving Sprocket
7 Pipe Plug 47 Drive Chain
8 Screw 48 Nut
9 Bolt 49 Gasket
10 Speed Sensor and Harness Bracket 53 Spring Pin
11 Speed Sensor Assembly 54 Hose Clamp
12 Speed Sensor 55 Hose Coupling
13 O-Ring 56 Oil Strainer
14 Locking Clip 58 Reduction Hub
15 Connector 59 Shift Fork Assembly
16 Motor Assembly 60 Shift Fork Facing
17 Oil Seal 61 Roller and Retainer
18 Bearing 66 Nut
19 Bolt 67 Plane Washer
20 Pump Assembly 68 Oil Seal
21 Output Shaft Assembly 71 Spacer
22 Bearing 72 Front Output Assembly
23 Ring Gear 73 Breather
24 Cover Assembly 74 Bolt
25 Nut 75 Front Adapter Assembly
26 Snap Ring 76 Snap Ring
27 Bearing 80 Snap Ring
28 Needle Bearing 81 Bearing
30 Clutch Coil Assembly 82 Input Shaft Assembly
31 Speed Gear 83 Sleeve Assembly
32 Oil Seal 84 Needle Bearing
33 Return Spring 86 Thrust Washer
34 Magnet 87 Retaining Ring
35 Clutch Housing 88 Thrust Plate
36 Snap Ring (option) 89 Sun Gear
37 Snap Ring 90 Gear Carrier Assembly
38 Lock-up Hub 97 Electric Shift Cam
39 Sleeve Return Spring 99 Spacer
40 Lock-up Collar

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5D2-20 TRANSFER CASE (PART TIME - 4408)

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE
MAINTENANCE OF TRANSFER
CASE LUBRICANT
1. Oil Level Check
• Clean the oil level plug and surrounding area.
• Remove the oil level plug and check whether
oil is drip out or not.
• Tighten the oil level plug.
Installation Notice
KAA5D220
Tightening Torque 4 - 6 N•m
(35 - 53 lb-in)

2. Oil Change
• Clean the oil level plug and surrounding area
• Place a suitable container under the transfer
case.
• Remove the oil and tighten the drain plug.

;;;;;;
Installation Notice

Tightening Torque 20 - 30 N•m

(15 - 22 lb-ft)

• Fill the oil through the oil level plug until oil
begins to drip out.
KAA5D230
• Tighten the oil level plug.
3. Cautions for oil level check and plugs tightening
• Do not use an impact wrench to remove or
tighten the oil level plug or drain plug since this
will damage the threads in the transfer case.

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 TRANSFER CASE (PART TIME - 4408) 5D2-21

4H AND 4L INDICATOR
When the ignition switch turns on, 4H and 4L indicators
turn on for 0.6 seconds and turn off.

Notice: If 4H and 4L indicators do not turn on, check

the related bulb, the wiring harness and TCCU.

KAA5D240

TCCU INSPECTION

Pin No. Operation Condition Voltage(V)

4H or 4L 4.75 - 5.35
J1 - 7
2H 0 - 0.50
4H indicator light ON < 1.00
J1 - 8
4H indicator light OFF > 11.00
2H or 4H 4.75 - 5.35
J1 - 13
4L 0 - 0.50
Clutch pedal applied < 0.50
J1 - 14
Clutch pedal released > 11.00
4L indicator light ON < 1.00
J1 - 15
4L indicator light OFF > 11.00
Motor OFF < 1.00
J1 - 16
Motor ON > 11.00
Motor OFF < 1.00
J1 - 17
Motor ON > 11.00
Auto locking hub ON > 11.00
J1 - 23
Auto locking hub OFF < 1.00

Notice:
• DC 12V for the TCCU operation should be
maintained.
• In case of J1-8 and J1-15, indicator light will turn
on for 0.6 second when turn the ignition switch ON.
• If 4H and 4L indicator lights remain turned on when
turn the ignition switch on or during driving, perform
the TCCU diagnosis.

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5D2-22 TRANSFER CASE (PART TIME - 4408)

TRANSFER CASE ASSEMBLY

1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the damper mounting bolt.
4. Remove the drain plug and drain the oil.
Reinstall the drain plug.
Installation Notice
Drain Plug Tightening 20 - 30 N•m
Torque (15 - 22 lb-ft)
Damper Tightening 30 - 40 N•m
KAA5D270 Torque (22 - 30 lb-ft)
Fill plug Tightening 4 - 6 N•m
Torque (35 - 53 lb-in)

5. Remove the breather hose.

KAA5D280

6. Disconnect the speedometer cable connector and

other cable connectors and wiring harnesses.

KAA5D290

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 TRANSFER CASE (PART TIME - 4408) 5D2-23

7. Support the transfer case with jack and remove

the front and rear propeller shafts from the transfer
case.
Installation Notice
81 - 89 N•m
Front
Tightening (60 - 66 lb-ft)
Torque 70 - 90 N•m
Rear
(52 - 66 lb-ft)

KAA5D300

8. Remove the center mounting nuts and end sides

mounting bolts of the cross member and then
remove the cross member.
Installation Notice
12 - 23 N•m
Tightening Torque(1)
(9 - 17 lb-ft)
6 - 8 N•m
Tightening Torque(2)
(53 - 71 lb-in)

KAA5D310

9. Remove the transfer case by removing the bolts

attaching the transfer case to the transmission.
Installation Notice

Tightening Torque 35 - 60 N•m

(26 - 44 lb-ft)

Notice: Apply long-term grease to the inner spline

of the transfer case input shaft.

10. Installation should follow the removal procedure

in the reverse order.

KAA5D320

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5D2-24 TRANSFER CASE (PART TIME - 4408)

TCCU
1. Disconnect the negative terminal from the battery.

KAA5D330

2. Remove the TCCU connector.

yyyy
;;;;
;;;;
yyyy KAA5D340

;;;;
yyyy
3. Remove the TCCU mounting bolt and remove the
TCCU.
• TCCU installation position : Under the driver’s
seat

;;;;
yyyy KAA5D350

;;;;
yyyy
4. Installation should follow the removal procedure
in the reverse order.
Notice: Be careful not to give any impact to the
TCCU body.

;;;;
yyyy
Installation Notice
Tightening Torque 10 N•m (89 lb-ft)

KAA5D360

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 TRANSFER CASE (PART TIME - 4408) 5D2-25

UNIT REPAIR
DISASSEMBLY PROCEDURE
Shift Motor Assembly
1. Separate the harness bracket.
2. Remove the shift motor mounting bolt and remove
the shift motor assembly.

KAA5D380

Companion Flange
1. Holding the companion flange, remove the nut and
washer and then remove the companion flange.
2. Remove the oil seal.
3. Remove the companion flange from the case
cover.

KAA5D390

Case Cover Assembly

1. Remove the cover mounting bolts(9), and the case
mounting bolts(5).
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.

KAA5D400

KAA5D410

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5D2-26 TRANSFER CASE (PART TIME - 4408)

3. Remove the clutch coil wiring from the connector.

4. Remove the clutch coil assembly mounting nut.

KAA5D420

5. Remove the snap ring and pull out the ball bearing
from the cover to remove the speed gear.

KAA5D430

6. Remove the clutch coil assembly and the oil seal

from the cover.

KAA5D440

7. Remove the speed sensor and the O-ring from

the case cover.

KAA5D450

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 TRANSFER CASE (PART TIME - 4408) 5D2-27

Transfer Case Assembly

1. Separate the shift motor shaft cam assembly and
the spring (1).

KAA5D460

2. Remove the clutch housing assembly from the

output shaft.
• Clutch Housing Component
(1) Retaining Ring
(2) Shift collar Hub
(3) Clutch Housing

KAA5D470

• Remove the shift cam from the shaft.

• Fix the shaft at the vise with the cam removed
and remove the torsion bar using a driver.

KAA5D480

3. Remove the 2WD/4WD lock up assembly, the lock

up fork and rail shaft from the output shaft.

KAA5D490

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5D2-28 TRANSFER CASE (PART TIME - 4408)

• 2WD/4WD Lock Up Assembly Component.

(37) Snap Ring
(38) Lock up Hub
(39) Return Spring
(40) Lock up Collar

KAA5D500

4. Remove the snap ring from the front output driven

sprocket and separate the snap ring and the
spacer.

KAA5D510

5. Remove the driving sprocket, the driven sprocket

and the driving chain from the front/rear output
shaft.

KAA5D520

6. Remove the oil pump assembly and the magnetic

from the output shaft.

KAA5D530

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 TRANSFER CASE (PART TIME - 4408) 5D2-29

• Remove the bolt and the retainer. Separate the

output shaft and rear pump cover.
• Remove the hose clamp and remove the hose
coupling cover from the pump housing.
• Remove the hose clamp, the hose coupling and
the strainer.
• Remove two pump pins and the spring from
the output shaft.
• Separate the front pump and remove the output
shaft.

KAA5D540

Reduction Shift Parts

1. Remove the reduction hub and reduction shift fork
assembly from the case.
2. Remove the 2 shill fork facings from the shift fork
assembly.
3. To remove the roller cam and pin, cut elf the plastic
retainer when disassembling the fork assembly.

KAA5D550

Front Output Assembly

1. Holding the companion flange, remove the nut and
washer and then remove the companion flange and
oil seal.
2. Remove the output shaft.

KAA5D560

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5D2-30 TRANSFER CASE (PART TIME - 4408)

Adapter, Input Shaft and Carrier Gear

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.

KAA5D570

Transfer Case Assembly (Front)

1. Remove the oil seal.
2. Remove the retaining ring and the ball bearing.
3. Remove the pin from the transfer case.
Notice: Be careful not to give any damage to the
case for removing the pin.

4. Remove the ring gear from the case using the

press.
Notice: Replace new part for installation.

KAA5D580

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 TRANSFER CASE (PART TIME - 4408) 5D2-31

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.

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5D2-32 TRANSFER CASE (PART TIME - 4408)

• Step wear : Heavy wear that produces a step

that can be seen or felt between adjacent
contact and non-contact surfaces.
• Uneven wear : Condition of localized, unevenly
distributed wear Includes hollows, shiny spots,
uneven polish and other visual indications.

3. Specific Inspection
• Referring to normal gear tooth face, specifically
inspect the uneven wear and chips of gear tooth.
Replace or repair if necessary.

KAA5D590

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 TRANSFER CASE (PART TIME - 4408) 5D2-33

4. Inspection of contact patterns

Description Normal Abnormal

Normal Wear

KAA5D600

End Face Wear

KAA5D610 KAA5D620

Traveling Face Wear

KAA5D630 KAA5D640

Upper Face Wear

KAA5D650 KAA5D660

Lower Face Wear

KAA5D670 KAA5D680

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5D2-34 TRANSFER CASE (PART TIME - 4408)

5. Chip pattern of the gear face

Description Patterns Action

Corner chip at drive face Repair

KAA5D690

Edge chip at drive face Repair

KAA5D700

Corner chip at coast face Repair

KAA5D710

Chip within contact pattern Replace

KAA5D720

Chip completely through Replace

tooth

KAA5D730

Side edge chip at drive face Replace

KAA5D740

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 TRANSFER CASE (PART TIME - 4408) 5D2-35

ASSEMBLY PROCEDURE
• Use special tools during assembly of oil seals and
bearings.
• Lubricate bearings, oil seals and bushings before
assembly.

Transfer Case Assembly

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.

KAA5D750

5. Make sure that all parts are correctly and firmly

installed into the case.

KAA5D760

Electric Shift Cam Parts

1. Insert the spacer into torsion spring.
2. Insert the end of the shift shaft into the spacer
smoothly.

KAA5D770

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5D2-36 TRANSFER CASE (PART TIME - 4408)

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.

KAA5D780

4. Push the end of the second spring to right and fix

it on the drive tang.

KAA5D790

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.

KAA5D800

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 TRANSFER CASE (PART TIME - 4408) 5D2-37

Adapter, Input Shaft and Carrier

1. Place the planet carrier assembly on work bench
to be the retaining ring mounting groove upward.
2. Install the sun gear with the hub end up into the
planet carrier assembly and rotate the sun gear
to make sure that gears are fully engaged.
3. Align the tabs and install the thrust plate into the
planet carrier assembly.
4. Install the retaining ring to the planet carrier
assembly.
5. Press the needle bearing into the input shaft and
press the new sleeve bearing into the input shaft
assembly.
6. Install the planet carrier assembly onto the input
shaft and install the thrust washer. Press the
bearing over input shaft.
7. After pressing the bearing, install the retaining
ring.
8. Press the pin into the front adapter.
9. Slowly press the oil seal into the front adapter.
10. Install the front adapter assembly.
Notice: After installation, make sure that snap ring
is correctly installed into the groove.

11. Position the input shaft assembly over front cover

KAA5D810 and engage into the bearing groove by expanding
the ends of snap ring.
12. Apply 1.6mm bead of sealant on the mounting
face for the transfer case and tighten the 6 bolts.
13. Install the breather.
Installation Notice
Item Tightening Torque
28 - 40 N•m
6 Bolts
(21 - 30 lb-ft)
4 - 7 N•m
Breather
(35 - 62 lb-in)

Front Output Shaft

Cross Sectional View

KAA5D820

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5D2-38 TRANSFER CASE (PART TIME - 4408)

Input Shaft
Cross Sectional View

KAA5D830

Front Output Shaft

1. Install the deflector on the yoke.
2. Position the output shaft in transfer case and install
the companion flange assembly, oil seal, washer
and nut.
3. Holding the companion flange, tighten the nut.
Installation Notice
Tightening Torque 346 - 380 N•m

KAA5D840

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.
KAA5D850
5. Install the output shaft spline into the reduction
hub and engage the output shaft end with input
shaft bearing.
Notice: For installation of the output shaft,
assemble the oil pump temporarily.

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 TRANSFER CASE (PART TIME - 4408) 5D2-39

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.
Notice: Flat 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.
KAA5D860
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.
Installation Notice

Tightening Torque 4 - 8.5 N•m

(35 - 75.5 lb-in)

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
KAA5D870
the snap ring into the shaft groove over spacer.

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5D2-40 TRANSFER CASE (PART TIME - 4408)

Lockup Shift
1. Install the lockup hub and return spring to the
lockup collar and 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.

KAA5D880

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
KAA5D890
and insert the retaining ring into the clutch collar
hub groove.

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 TRANSFER CASE (PART TIME - 4408) 5D2-41

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 mark up and press into the cover
until upper end of bearing is 40.47 - 40.97 mm
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
KAA5D900
clutch coil assembly.
• Install the clutch coil assembly inside the cover
and tighten 3 nuts.
Installation Notice

Tightening Torque 8 - 11 N•m

(71 - 97 lb-in)

• Install the bearing and motor bearing into the

cover.

Cover Assembly
1. Install the return spring over rail shaft in the transfer
case.
2. Insert the magnet into the transfer case slot.
3. Apply 1.6 mm 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.

4. Install the cover onto the transfer case as follows:

• Align the cover bores with transfer case pins.
KAA5D910 • Align the cover bearings with output shafts.
• Align the cover blind hole with rail shaft and
make sure that return spring is not cocked.

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5D2-42 TRANSFER CASE (PART TIME - 4408)

5. Tighten 9 bolts positioning identification tag and

wiring clip.
Installation Notice

Tightening Torque 28 - 40 N•m

(21 - 30 lb-ft)

6. Install the speed gear over output shaft spline in

the cover assembly.
7. Press the new oil seal into the cover assembly.

KAA5D920

External Electric Shift

1. Align the motor with shift shaft and position the
motor assembly onto the cover.
2. Install the motor to the shift shaft and contact
cover and rotate the motor clockwise direction to
check correct engagement.

KAA5D930

3. Insert the O-ring on the speed sensor assembly

to the cover.
4. Install the bracket to the motor assembly and
tighten 3 bolts.
Installation Notice

Tightening Torque 8 - 11 N•m

(71 - 97 lb-in)

KAA5D940

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 TRANSFER CASE (PART TIME - 4408) 5D2-43

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.
Installation Notice
Front Flage Nut 210 - 240 N•m
Tighteng Torque (155 - 177 lb-ft)
Rear Flage Nut 310 - 340 N•m
Tighteng Torque (229 - 251 lb-ft)

Notice: Apply Loctite #262 to nut before

installation.

SSANGYONG MY2002