SSANGYONG KORANDO 1997 Service Repair Manual

SSAMGYONG MY2002
5C-6 CLUTCH
CLUTCH DISC
Preceding Work : Removal of the transmission
KAA5C040
1 Clutch Disc
2 Clutch Cover Assembly
3 Release Bearing
4 Clutch Housing5 Washer
6 Bolt........................................... 23 Nm (17 lb-ft)
7 Washer
8 Bolt........................................... 54 Nm (40 lb-ft)
Tools
602 589 00 40 00 Engine Lock
661 589 00 15 00 Centering Pin

CLUTCH 5C-7
SSANGYONG MY2002
Removal & Installation Procedure
Tools Required
602589 00 40 00 Engine Lock
1. Remove the starter motor. Install the special tool
to the flywheel through the starter motor mounting
holes.
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.
Tools Required
Centering Pin 661 589 00 15 00
KAA5C050
KAA5C060
KAA5C070
KAA5C080
Tightening Torque15 - 18 Nm
(11 - 13 lb-ft)
Tightening Torque 54 Nm (40 lb-ft)

SSAMGYONG MY2002
5C-8 CLUTCH
5. Unscrew the bolts and remove the clutch cover,
pressure plate and clutch disc.
Notice: Be careful not to drop the pressure plate
and clutch disc.
Installation Notice
6. Installation should follow the removal procedure
in the reverse order.
Notice:
Before installation, clean oil and grease on the
flywheel surface.
Do not clean the clutch disc and release bearing
in solvent.
2. Clutch Disc
Check the facing for rivet looseness, excessive
runout, sticks, oil and grease.
Measure the rivet head depth.
If out limit, replace the disc.
Inspection Procedure
1. Clutch Cover
Check the diaphragm spring tip for wear and
height unevenness.
Check the pressure plate surface for wear, crack
and discoloration.
Check the strap plate rivet for looseness and
replace the clutch cover if loosened.
KAA5C090
KAA5C100
KAA5C110
Tightening Torque21 - 27 Nm
(15 - 20 lb-ft)
Wear Limit 0.3 mm
Unevenness Limit 0.8 mm

CLUTCH 5C-9
SSANGYONG MY2002
3. Clutch Release Bearing
The release bearing is permanently lubricated
and requires no cleaning.
Check the bearing for sticks, damage, abnormal
noise, turning drag and wear.
4. Release Fork
If there is abnormal wear in contact point with
bearing, replace the release fork.
KAA5C120

SSAMGYONG MY2002
5C-10 CLUTCH
1 Snap Pin
2 Clevis Pin
3 Clevis
4 Lock Nut
5 Flange Nut.................... 8 - 18 Nm (6 - 13 lb-ft)
6 Push Rod
7 Cylinder Body
8 Oil Pipe..................... 15 - 18 Nm (11 - 13 lb-ft)
MASTER CYLINDER
9 Clamp
10 Reservoir
11 Spring
12 Piston Assembly
13 Boot
14 Plate
15 Snap Ring
KAA5C130
Notice: Do not disassemble the No. 12.

CLUTCH 5C-11
SSANGYONG MY2002
Removal & Installation Procedure
1. Draw out the fluid.
2. Pull out the snap pin and clevis pin from the clutch
pedal connection.
3. Remove the clutch tube.
Installation Notice
Notice: Be careful not the fluid contact a painted
surface.
4. Remove the master cylinder mounting nuts and
pull off the master cylinder.
Installation Notice
5. Check the clutch pedal operation.
6. Bleed the clutch system.
KAA5C140
Tightening Torque15 - 18 Nm
(11 - 13 lb-ft)
Tightening Torque8 - 18 Nm
(6 - 13 lb-ft)

SSAMGYONG MY2002
5C-12 CLUTCH
1 Snap Pin .................................................Replace
2 Clevis Pin......................................Apply Grease
3 Master Cylinder Push Rod
4 Gasket
5 Nut ............................ 16 - 32 Nm (12 - 24 lb-ft)
6 Spring Washer
7 Bolt................................ 8 - 18 Nm (6 - 13 lb-ft)
8 Fulcrum Pin
CLUTCH PEDAL
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 Clutch Interlock Switch
KAA5C150
Notice: Assembly should follow the disassembly procedure in the reverse order.
Grease specification: Long - term grease (T/Mn DBL6611.00)

CLUTCH 5C-13
SSANGYONG MY2002
Inspection Procedure
1. Pedal Stroke (A).
Installation Notice
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.
2. Pedal Height (B).
Installation Notice
Notice: To adjust the pedal height, loosen the lock
nut (C) of the stopper bolt (D) and turn the stopper
bolt until the height is correct.
3. Pedal Free Play (E).
Installation Notice
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.
KAA5C160
Max. Stroke 158 mm
Height
(From the Floor Carpet)147 - 187 mm
Free Play 5 - 10 mm

CLUTCH 5C-15
SSANGYONG MY2002
Replace
Repair or Replace
Replace
Replace
Adjust
Repair or Replace
Replace Excessive Wear of Facing
Hard or Oily Facing
Damaged Pressure Plate or Flywheel
Damaged or Burnt Diaphragm Spring
Clutch Pedal Free play Insufficient
Faulty Operation of Clutch Pedal
Worn or Damaged Clutch DiscAction Checks
DIAGNOSIS
CLUTCH SLIPS
Replace
Repair or Replace
Repair or Replace
Replace
Adjust Vibration or Excessive Run-out of Disc
Rust or Wear of Disc Spline
Oily Facing
Damaged Diaphragm Spring
Excessive Clutch Pedal Free playAction Checks
POOR DISENGAGEMENT
Adjust Pedal Freeplay
Repair Release Cylinder
Repair or Replace
Repair as Necessary
Replace Excessive Clutch Pedal Free play
Faulty Clutch Release Cylinder
Worn Disc, Excessive Run-out, Damaged Lining
Dirty or Burred Splines on Input Shaft or Clutch Disc
Damaged Clutch Pressure PlateAction Checks
HARD TO SHIFT OR WILL NOT SHIFT
Repair or Replace
Replace
Replace
Replace
Replace
Repair or Replace
Tighten or Replace Oily Facing
Hard or Faulty Facing
Burnt Torsion Spring
Faulty Pressure Plate
Bent Clutch Diaphragm Spring
Hard or Bent Flywheel
Engine Mounts Loose or Burnt LeverAction Checks
CLUTCH CHATTERS WHEN STARTING

SSAMGYONG MY2002
5C-16 CLUTCH
Lubricate or Replace
Lubricate or Replace
Repair Poor Lubrication on Clutch Cable
Poor Lubrication on Pedal Shaft
Poor Lubrication on Clutch PedalAction Checks
DIFFICULT PEDAL OPERATION
Insufficient Clutch Pedal Free play
Excessive Wear of Facing
Worn or Damaged Release Bearing
Poor Lubrication Contact Surface of Bearing
Faulty Installation of Clutch Assembly or Bearing
Damaged Pilot Bushing Not Using the Clutch
After Disengagement
When Disengaging
Clutch Pedal is Partially Depressed
and Vehicle Speed is ReducedAction Checks
CLUTCH NOISY
Adjust
Replace
Replace
Replace
Repair
Replace