SsangYong Stavic / SsangYong Rodius (2005 year). Service manual - part 360

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AFFECTED VIN

47

TOD

STAVIC - 2004.09

4D

20. Install the magnet in the slot in the front case just above

the oil filter leg.

21. Install the front output shaft in the front case.

22. Install the thrust washer on the rear output shaft.

23. Install the chain, drive sprocket and driven sprocket as

an assembly over the output shaft.

 [Notice]

The driven sprocket (on the front output shaft) must be
installed with the marking REAR facing toward the rear case,
if so marked.

Drive sprocket has a bushing pressed into it.

19. Install the output shaft and oil pump in the input shaft.

Make sure that the internal splines of the ouput shaft
engage the internal splines of the high-low shift collar.

Make sure that the oil pump retainer arm and oil filter leg
are in the groove and slot of the front case.

18. Inspect the outside surfaces and bore of the oil pump.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

48

TOD

STAVIC - 2004.09

4D

26. Install snap ring onto the rear output shaft. Start the snap

ring over the spline and use the wave spring to seat the
snap ring in the snap ring groove.

If the snap ring will not install, the thrust washer inside
the clutch pack may not be seated properly.

27. Install wave spring, insulator washer and armature. (Three

offset slots must align with housing to be installed)

24. Install tone wheel onto the front output shaft. Make sure

the spline on the tone wheel engages the spline on the
front output shaft.

25. Install clutch pack assembly onto the rear output shaft.

Make sure the spline of the clutch pack engages to the
spline of the sprocket.

 [Notice]

Three slots on the thrust washer must be aligned with the
three tabs on the clutch pack housing.

28. Install apply cam onto the rear output shaft,

29. Install three balls into the apply cam.

30. Install cam and coil housing assembly onto rear output

shaft.

31. Install thrust bearing assembly onto output shaft.

32. If removed, drive the front output shaft ball bearing into

the rear cover bore with Front Shaft Needle Bearing
Replacer and Driver Handle.

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49

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STAVIC - 2004.09

4D

43a

37. Slide the spring spacer on the camshaft and position it

beneath the drive tang.

38. Place the torsion spring on the camshaft. Position the

first spring tang to the left of the camshaft drive tang.

39. Rotate the second spring tang clockwise past the drive

tang.

35. Install the clutch coil from inside the rear case until the

wire and studs extend through the cover.

33. If removed, install the rear output bearing in the rear case

bore. Drive the bearing into the rear case bore with Output
Shaft Bearing Replacer and Driver Handle. Make sure
that the bearing is not cocked in the bore.

34. Install the internal snap ring that retains the bearing to

the rear case.

36. Install the washers and nuts and tighten.

Installation Notice

 [Notice]

Do not kink or trap the wire while seating the clutch coil to
the case.

Tightening torque

8 - 11 Nm

 (71 - 97 lb-in)

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EFFECTIVE DATE

AFFECTED VIN

50

TOD

STAVIC - 2004.09

4D

42. Install the pin on the tang end of the helical cam into the

hole in the front case. Position the torsion spring tangs
so that they are pointing toward the top side of the
transfer case and just touching the high-low shift fork.

40. Push the torsion spring and sleeve in as far as it will go.

41. Install the helical cam and slide the drive tang between

the torsion spring tangs as far as it will go.

43. Install the shift rail through the high-low shift fork and

make sure that the reverse gear shift rail is seated in the
front case bore.

 [Notice]

Do not bend the helical cam during installation to the front
case because of possible damage to the pin at the tang end of
the motor shaft.

44. Install upper and lower speed sensors into the cover.

Feed the coil wire through the upper speed sensor wire
shield.

45. Install upper tone wheel, speedometer gear and rear

output seal. Use Output Shaft Seal Replacer and Driver
or equivalent to install seal.