Daewoo Korando. Instruction - page 294
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 the
drive tang.
101
Torsion Spring
102
Spacer
103
Shift Shaft
5. Push the torsion spring and spacer together back them
completely.
6. Slide the electric 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) 5D1-27
Adapter, Input Shaft and Carrier
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. 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.
82 Sleeve Bearing
83 Needle Bearing
84 Input Shaft
85 Thrust Washer
86 Carrier Gear Assembly
87 Retaining Ring
88 Thrust Plate
89 Sun Gear
90 Planet Carrier Assembly
111 Case
5D1-28 TRANSFER CASE (PART TIME 4408)
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 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.
75
Snap Ring
76
Oil Seal
77
Spiral Pin
78
Front Adapter
82
Sleeve Bearing
83
Needle Bearing
84
Input Shaft
Item
6 Bolts
Breather
Tightening Torque
28 - 48 Nm
8 - 20 Nm
TRANSFER CASE (PART TIME 4408) 5D1-29
Front Output Shaft
1. Press the deflector onto 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.
65 Nut
66 Washer
67 Oil Seal
70 Companion Flange
71 Output Shaft (Front)
111 Transfer 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.
Notice
For installation of the output shaft, assemble
the oil pump temporarily.
