Daewoo Musso. Manual — part 294

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

<Companion Flange>

1. Holding the companion flange, remove the nut and washer

and 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

25 Cover

6 Bolt
7 Washer
8 Bolt
9 Sensor and Harness Bracket

10 Sensor Assembly

11 Speed Sensor

12 O-ring
13 Motor Assembly
25 Cover

<Extension Electric Shift>

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 and

identification 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.

<Cover Assembly>

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)

<Lock-up Shift Parts>

1. Remove the retaining ring and clutch housing from the shift

collar 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)

<Drive Chains>

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.

<Pump Parts>

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