lock SSANGYONG MUSSO 2003 Service Manual

MANUAL TRANSMISSION 5B-41
5. Check the shift mechanism parts as follows : Wear of the shift shaft.
Wear of the detent/guide plate and offset lever.
Check 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.
Check 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.

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.

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

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

5C-6 CLUTCH
COMPONENT LOCATOR
CLUTCH ASSEMBLY
1 Clutch Disc
2 Clutch Cover
3 Clutch Housing
4 Release Bearing
5 Release Fork Pivot
6 Release Cylinder
7 Release Fork Boot 8 Bolt
9 Release Fork
10 Bolt 11 Spring Lock Washer
12 Transmission Input Spline
13 Release Bearing Contacting Surface
14 Contacting Point of Release Fork and Pivot
Notice
Apply the long-term grease (DBL 6811.00) to No.12,13 and 14.

CLUTCH 5C-9
CLUTCH DISC Preceding Work : Removal of the transmission
1 Clutch Disc
2 Clutch Cover Assembly
3 Release Bearing
4 Clutch Housing
Tools 602 589 00 40 00 Engine Lock661 589 00 15 00 Centering Pin 5 Washer
6 Bolt
........................................................... 23 Nm
7 Washer
8 Bolt ........................................................... 44 Nm

5C-10 CLUTCH Removal & Installation Procedure
1. Remove the starter motor. Install the special tool to theflywheel through the starter motor mounting holes.
Tightening Torque 47 Nm
Engine Lock 602 589 00 40 00
2. Unscren the release cylinder mounting bolts and remove the release cylinder. Installation Notice
3. Unscrew the clutch housing bolts and remove the clutch housing, release fork and release bearing.Installation Notice
4. Insert the centering pin into the clutch spline. Loosen the clutch cover bolts 1/2 turn in crisscross sequence until the spring tension is released. Notice
Do not remove the bolts at a time, or clutchcover can be damaged or deformed.
Centering Pin 661 589 00 15 00
Tightening Torque 30 - 40 Nm

CLUTCH 5C-13
MASTER CYLINDER
1 Snap Pin
2 Clevis Pin
3 Clevis
4 Lock Nut
5 Flange Nut ........................................... 30-40 Nm
6 Push Rod
7 Cylinder Body
8 Oil Pipe ................................................ 15-18 Nm 9 Clamp
10 Reservoir
11 Spring
12 Piston Assembly
13 Boot
14 Plate
15 Snap Ring
Notice Do not disassemble the No.12.

CLUTCH 5C-15
CLUTCH PEDAL
1 Snap Pin................................................ Replace
2 Clevis Pin ...................................... Apply Grease
3 Master Cylinder Push Rod
4 Gasket
5 Nut ....................................................... 16-22 Nm
6 Spring washer
7 Bolt ........................................................ 8-18 Nm
8 Fulcrum Pin 9 Turn Over Spring
..........................Apply Grease
10 Bushing ......................... Replace, Apply Grease
11 Full Stroke Stopper Contact Pad
12 Clutch Pedal
13 Pedal Pad
14 Pedal Mounting Bracket
15 Stopper Bolt .......................................... 21-25Nm
16 Clutch Interlock Switch
Notice
Assembly should follow the disassembly procedure in the reverse order.
Grease specification : Long - term grease (T/Mn DBL6611.00)

5C-16 CLUTCH
Inspection Procedure
1. Pedal Stroke (A).Notice
To adjust the pedal stroke, loosen the lock nut (H) of the
interlock switch (G) and turn the two lock auto until the stroke is correct.
Max. Stroke 158 mm
2. Pedal Height (B). Notice
To adjust the pedal height, loosen the lock nut (C) of the
stopper bolt(D) and turn the stopper bolt until the height iscorrect.
Height (From the Floor Carpet) 147 - 187 mm
3. Pedal Free Play (E). Notice
To adjust the pedal free play, loosen the lock nut (F) of the
master cylinder and turn the push rod until the free play is correct.
4. Check the fulcrum pin and the bushing for wear, the pedal for bending and the spring for damage.
Free Play 5 - 10 Nm