SSANGYONG MUSSO 1998 Workshop Repair Manual

5C-8 CLUTCH
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
BLEEDING OF CLUTCH SYSTEM
Bleeding procedure
Notice
Keep the fluid level over ‘MAX’ in reservoir during
bleeding operation.
Do not let fluid contact a painted surface.
1. Remove the air bolt cap of the release cylinder.
Connect a vinyl tube to the bolt.
2. Insert the other end of the tube in a vacant container.
3. Slowly depress the clutch pedal several times.
4. With clutch pedal fully depressed, open the air bolt and
release air rind fluid in the fluid line,
5. Repeat this procedure until there are no more air bubbles
in the fluid flows.

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 Lock
661 589 00 15 00 Centering Pin5 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 the
flywheel 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-11
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
Tightening Torque 21 - 27 Nm
6. Installation should follow the removal procedure in the
reverse order.
Notice
lBefore installation, clean oil and grease on the
flywheel surface.
lDo not clean the clutch disc and release bearing in
solvent.

5C-12 CLUTCH
Inspection Procedure
1. Clutch Cover
lCheck the diaphragm spring tip for wear and height
unevenness.
lCheck the pressure plate surface for wear, crack and
discoloration.
lCheck the strap plate rivet for looseness and replace
the clutch cover if loosened.
Unevenness Limit 0.8 mm
2. Clutch Disc
lCheck the facing for rivet looseness, excessive runout,
sticks, oil and grease.
lMeasure the rivet head depth.
If out limit, replace the disc.
3. Clutch Release Bearing
lThe release bearing is permanently lubricated and
requires no cleaning.
lCheck the bearing for sticks, damage, abnormal noise,
turning drag and wear.
4. Release Fork
lIf there is abnormal wear in contact point with bearing,
replace the release fork.
Wear Limit 0.3 mm

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 Nm9 Clamp
10 Reservoir
11 Spring
12 Piston Assembly
13 Boot
14 Plate
15 Snap Ring
Notice
Do not disassemble the No.12.

5C-14 CLUTCH
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
Tightening Torque 15 - 18 Nm
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
Tightening Torque 8 - 18 Nm
5. Check the clutch pedal operation.
6. Bleed the clutch system.

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 Pin9 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 is
correct.
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

CLUTCH 5C-17
CLUTCH OIL CHAMBER
1 Clutch Master Cylinder
2 Hydraulic Tube
3 Bolt4 Clutch Oil Chamber
5 Hydraulic Tube
6 Clutch Release Cylinder
Notice
lInstallation should follow the removal procedure in the reverse order.
lWhen installing, perform the bleeding procedures from chamber cylinder and release cylinder.