SSANGYONG MUSSO 1998 Workshop Repair Manual

5B-34 MANUAL TRANSMISSION
COUNTER SHAFT
Disassembly Procedure
1. Using a hydraulic press and special tool, remove the front
bearing assembly from the counter shaft.
2. Check and clean all removed parts and replace if necessary.
Assembly Procedure
1. Using a hydraulic press and installer, press the front bearing
assembly onto the counter shaft.
2. Install is as follows :
lInstall a new O-ring on the counter shaft outer race and
lubricate it.
lUsing a installer, lightly tap the race into its bore until the
O-ring is compressed.
lInstall the race to be fully seated on the inside of the
case.

MANUAL TRANSMISSION 5B-35
EXTENSION HOUSING
Disassembly Procedure
1. Remove the vent from the extension housing.
2. Remove the O-ring and steel ring from the rear of the
extension housing.
3. Check and clean all removed parts and replace if necessary.
Assembly Procedure
1. Install the O-ring and steel ring to the rear of the extension
housing.
2. Install the vent to the extension housing.

5B-36 MANUAL TRANSMISSION
SHIFT COVER
Disassembly Procedure
1. Using a hammer and a pin punch (3/16) remove the selector
arm roll pin.
2. Before removal, note the correct position of the interlock
plate and selector arm and remove the shift shaft.
3. Check and clean all removed parts and replace if necessary.
Assembly Procedure
1. If the shaft cup plug was removed, apply plug outer surface
with sealer and install it into the cover.
2. Install the fork pads and selector plates onto the 1-2 and 3-
4 shift forks.
3. Assemble the sift cover parts as follows :
Push the shift shaft into the cover until the front of the shaft
is at the inside of the cover.

MANUAL TRANSMISSION 5B-37
lInstall the 1-2 shift fork and its selector plate.
lPush the shift shaft through the 1-2 shift fork.
lPlace the selector arm and interlock plate in the cover
Note the position of the interlock plate and selector arm.
lPush the shift shaft through the 3-4 shift fork.

5B-38 MANUAL TRANSMISSION
lInstall the 3-4 shift fork and its selector plate.
lPush the shift shaft through the 3-4 shift fork.
lInstall the roll pin that fixes the selector arm to the shift
shaft.
4 . Check the shift cover parts for proper assembly as follows :
lInsert a pin punch (3/16) into the offset lever hole of
the shift shaft.
lPlace the shift cover to the flat ground and rotate the
shift shaft so that the punch is vertical.

MANUAL TRANSMISSION 5B-39
lSelector arm should be aligned with the 3/4 shift fork
selector plate.
5. Lubricate and install the O-ring on the rear of the shift cover.

5B-40 MANUAL TRANSMISSION
INSPECTION OF COMPONENTS
Inspection Procedure
1. Clean all parts with solvent and dry them with compressed
air. Check the following parts for cracks and damaged
sealing surfaces.
lCase
lExtension housing
lShift Cover
lInput bearing retainer
lCounter shaft rear bearing retainer
2. Check the parts which support bearings and shafts for
excessive wear and replace them if necessary.
3. Check the bearing surfaces of the following parts ;
lInput shaft
lMain shaft and its gears
lCounter shaft and 5th drive gear
4. Check the reverse idler shaft and its gears.
Notice
Replace excessive wear parts and do not file on the
hardened surface and precision ground.

MANUAL TRANSMISSION 5B-41
5. Check the shift mechanism parts as follows :
lWear of the shift shaft.
lWear of the detent/guide plate and offset lever.
lCheck worn edges on the following parts :
- Selector arm.
- Interlock plate.
- Selector plates for the 1-2 and 3-4 shift forks.
- 5-R shift lever and the rollers on the reverse fork and
the 5th shift rail/fork.
lCheck worn mating surfaces on the following parts :
- 1-2 shift fork, pads and synchronizer sleeve.
- 3-4 shift fork, pads and synchronizer sleeve.
- 5th shift rail/fork pads and synchronizer sleeve.
- Reverse fork and reverse idler gear sleeve.

5B-42 MANUAL TRANSMISSION
6. Check the following Bearing for excessive war:
lCrankshaft pilot bushing for the front of the inputshaft.
lClutch release bearing.
lInput shaft bearing.
lMain shaft pilot bearing rollers.
lMain shaft thrust Bearing and its surfaces.
lSpeed gear roller bearing on the main shaft.
lMain shaft rear bearing.
lCounter shaft front and rear bearings.
7. Check the gear tooth surfaces of all gear sets.
8. Check the reverse gear set surfaces. Check the surfaces
of gear teeth for excessive wear, pitting, scoring and spalling
and replace if necessary.

MANUAL TRANSMISSION 5B-43
9. Take apart the three synchronizer assemblies and check :
lThe 1-2 synchronizer.
lThe 5th blocking ring.
10. Check the fit between the hub and sleeve of each
synchronizer
lExcessively tight or loose hub-to-sleeve fit.
lWear of the cone clutch surfaces of brass blocking
rings and gears.
11. Measure the clearance between the blocking ring and the
speed gear
lNew 1-2 blocking ring : 0.87-1.4mm
lNew 3-4 blocking ring : 0.88-1.5mm
Notice
Excessive wear of the blocking ring or the speed gear cone
surface will cause shift block-out gear clash.