lock SSANGYONG MUSSO 1998 Workshop Repair Manual

5B-28 MANUAL TRANSMISSION
7. Using a screwdriver, remove the spiral retaining ring.
8. Remove the thrust washer and three-piece 2nd speed
blocking ring assembly.
9. For correct reassembly, place an alignment mark on the
1-2 synchronizer hub and sleeve.
10. Remove the 1-2 synchronizer sleeve from the hub with
following parts :
lThe anti-rattle ball and spring.
lThe three keys.
lOne of the 3 springs.
11. Using a hydraulic press and puller plate, remove the 5th
speed driven gear from the main shaft.

MANUAL TRANSMISSION 5B-29
12. Remove the main shaft rear bearing assembly from the
shaft.
13. Remove the 1st speed gear and bearing.
14. Remove the inner race.
15. Remove the tree-piece 1st speed blocking ring assembly
and remaining synchronizer spring.
16. Check and clean all removed parts and replace if
necessary.

5B-30 MANUAL TRANSMISSION
Assembly Procedure
1. When assemble the synchronizer, make sure that the hubs
and sleeves are matched and the 3 keys are installed
properly. Also align blocking rings with keys during
installation.
Notice
Before assembly, coat all parts with lubricant. In case of the
paper-lined blocking rings, soak them in DexronII/III before
installation.
2. Assemble the following parts :
l1st speed blocking ring.
lAlignment pin and 1st speed gear bearing race.
l1st speed gear and its bearing.
3. Install the rear bearing assembly to the main shaft.
4. Using a hydraulic press and installer, press the 5th driven
gear onto the main shaft. While the main shaft is still on the
press bed, install the 5th driven gear snap ring. If the snap
ring does not fit completely, continue pressing the 5th driven
gear.
5. Install the following parts :
l2nd speed blocking ring assembly.
lThrust washer for the blocking ring inner cone.
lSpiral retaining ring (Use special tools).
l2nd speed gear spacer, bearing and gear.
l2nd gear thrust washer and snap ring.
l3rd speed gear spacer, bearing and gear.
l3rd speed blocking ring.

MANUAL TRANSMISSION 5B-31
6. Using a hydraulic press and installer, install the 3-4
synchronizer hub onto the main shaft.
Notice
Align the blocking ring with the synchronizer keys while
installing the hub.

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.

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.

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.

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
f15.87 mm
14.0 mm
f17.46 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 this
cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK
unless otherwise noted.
Application
Type
Max. Pedal Stroke
Pedal Free Play
Type
Thickness of Disc
Stroke
Inner Diameter
Stroke
Inner 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 Lock661 589 00 15 00
Centering Pin