SSANGYONG MUSSO 2003 Service Manual

5B-42 MANUAL TRANSMISSION
6. Check the following Bearing for excessive war: Crankshaft pilot bushing for the front of the input shaft.
Clutch release bearing.
Input shaft bearing.
Main shaft pilot bearing rollers.
Main shaft thrust Bearing and its surfaces.
Speed gear roller bearing on the main shaft.
Main shaft rear bearing.
Counter 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 : The 1-2 synchronizer.
The 5th blocking ring.
10. Check the fit between the hub and sleeve of each synchronizer
Excessively tight or loose hub-to-sleeve fit.
Wear of the cone clutch surfaces of brass blocking rings and gears.
11. Measure the clearance between the blocking ring and the speed gear
New 1-2 blocking ring : 0.87-1.4mm
New 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.

5B-44 MANUAL TRANSMISSION
12. Check for gear clash on the synchronizer sleeve teeth orthe clutch teeth on the speed gear.
13. Check the synchronizer sleeve and gear clutch tooth for hop-out.

MANUAL TRANSMISSION 5B-45
PRE-INSTALLATION CHECKS Checking Procedure
1. Separate the clutch release fork from the pivot and removethe pivot from the clutch housing.
2. Check the pivot. Fork and release bearing.
3. Check the pressure plate spring. Notice Inspect each parts and replace the excessively worn parts.
4. Check the clutch housing alignment as follows : Place the magnetic base on the pressure plate spring.
Check the housing bore alignment.
- Place the dial indicator on the bore.
- By rotating the crankshaft one revolution, record the
dial indicator reading.

5B-46 MANUAL TRANSMISSION
Check the housing face alignment.
- Place the dial indicator on the housing face.
- By rotating the crankshaft one revolution, record the
dial indicator reading.
NoticeIf the reading is greater than 0.010 inch, insert the shim between the engine and clutch housing and adjust thealignment.
5. Check the following parts : Pressure plate spring assembly
Disc
Flywheel
Input shaft pilot bearing
Notice
Replace the excessively worn parts.
6. Lubricate the clutch release bearing bore, fork pivot head during assembly.

Type Clutch Pedal Clutch Disc Clutch Master Cylinder Clutch Release Cylinder Clutch FluidDescription
Hydraulic
Suspended 158 mm
5 - 10 mm
Single Dry Diaphragm
9.85 - 10.2 mm 9.2 mm
19.8 mm
15.87 mm
14.0 mm
17.46 mm
SAE J1703 / DOT3
SECTION 5C
CLUTCH
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 General Specifications . . . . . . . . . . . . . . . . . . 5C-1
Fastener Tightening Specifications . . . . . . . . . 5C-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5C-3 Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5C-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Clutch Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4
Poor Disengagement . . . . . . . . . . . . . . . . . . . 5C-4
Hard to Shift or Will not Shift . . . . . . . . . . . . . . 5C-4
Clutch Chatters When Starting . . . . . . . . . . . . 5C-4
Difficult Pedal Operation . . . . . . . . . . . . . . . . . 5C-5
SPECIFICATIONS
GENERAL SPECIFICATIONS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
Application
Type Max. Pedal StrokePedal Free Play
TypeThickness of Disc Stroke Inner DiameterStrokeInner DiameterFree
With Load
Clutch Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5
Component Locator . . . . . . . . . . . . . . . . . . . 5C-6 Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . 5C-6
Pedal and Master Cylinder . . . . . . . . . . . . . . . 5C-7
Maintenance and Repair . . . . . . . . . . . . . . . 5C-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 5C-8
Bleeding of Clutch System . . . . . . . . . . . . . . . 5C-8
Clutch Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 5C-13
Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15
Clutch Oil Chamber . . . . . . . . . . . . . . . . . . . 5C-17

5C-2 CLUTCHFASTENER TIGHTENING SPECIFICATIONS
Application
Clutch Cover Bolt Clutch Housing Bolt Clutch Release CylinderMaster Cylinder Nut
Clutch Tube NutPedal Push Rod Nut Pedal Mounting
N 

 m
37 47
30 - 40 8 - 18
15 - 18 16 - 22
8 - 18
21 - 25
Bracket Bolt Stopper Bolt

CLUTCH 5C-3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
602 589 00 40 00 Engine Lock 661 589 00 15 00
Centering Pin

5C-4 CLUTCHChecks
Oily Facing Hard or Faulty Facing
Burnt Torsion Spring Faulty Pressure Plate Bent Clutch Diaphragm SpringHard or Bent FlywheelEngine Mounts Loose or Burnt Lever Action
Adjust Pedal Freeplay
Repair Release Cylinder Repair or Replace
Repair as Necessary Replace
Checks
Excessive Clutch Pedal Free play Faulty Clutch Release Cylinder Worn Disc, Excessive Run-out, Damaged LiningDirty or Burred Splines on Input Shaft or Clutch DiscDamaged Clutch Pressure Plate Checks
Vibration or Excessive Run-out of DiscRust or Wear of Disc Spline Oily Facing Damaged Diaphragm SpringExcessive Clutch Pedal Free play DIAGNOSIS
CLUTCH SLIPS
Checks
Excessive Wear of Facing Hard or Oily FacingDamaged Pressure Plate or FlywheelDamaged or Burnt Diaphragm SpringClutch Pedal Free play Insufficient Faulty Operation of Clutch Pedal Worn or Damaged Clutch Disc Action
Replace
Repair or Replace ReplaceReplaceAdjust
Repair or Replace Replace
POOR DISENGAGEMENT
Action
Replace
Repair or Replace Repair or Replace Replace
Adjust
HARD TO SHIFT OR WILL NOT SHIFT
CLUTCH CHATTERS WHEN STARTING
Action
Repair or Replace
Replace Replace Replace Replace
Repair or Replace
Tighten or Replace

CLUTCH 5C-5
Checks
Poor Lubrication on Clutch Cable Poor Lubrication on Pedal Shaft Poor Lubrication on Clutch Pedal Not Using the Clutch
After Disengagement When Disengaging DIFFICULT PEDAL OPERATIONAction
Lubricate or Replace Lubricate or Replace
Repair
CLUTCH NOISY
Checks Action
Adjust
Replace ReplaceReplace Repair
Replace
Insufficient Clutch Pedal Free play Excessive Wear of Facing Worn or Damaged Release BearingPoor Lubrication Contact Surface of BearingFaulty Installation of Clutch Assembly or BearingDamaged Pilot Bushing
Clutch Pedal is Partially Depressed
and Vehicle Speed is Reduced