Daewoo Musso. Manual — part 297
![](/vehicles/epme/qux/oho/umee.png)
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
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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
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TRANSFER CASE (PART TIME 4408) 5D1-29
Front Output Shaft
1. Position the output shaft in transfer case and install the
companion 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.
Notice
For installation of the output shaft, assemble
the oil pump temporarily.
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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.
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.
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
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