wheel bolts SSANGYONG MUSSO 1998 Workshop User Guide

FRONT DISC BRAKES 4D-3
Removal & Installation Procedure
1. MANDO Brake
Tightening Torque 25 - 35 Nm
2. PBR Brake
Remove the eye-hose bolt and disconnect the hose.
Installation Notice
Tightening Torque 15 - 18 Nm
3. Remove the wheel speed sensor (for ABS vehicies).
Installation Notice
Tightening Torque 6 - 8 Nm
4. Remove the mounting bolts and then caliper assembly.
Installation Notice
Tightening Torque 85 - 105 Nm
Remove the hose mounting nut and disconnect the hose.
Installation Notice

REAR DISC BRAKES 4E-3
Tightening Torque 15 - 18 Nm
Tightening Torque 85 - 105 Nm
Removal & Installation Procedure
1. Remove the eye-hose bolt and disconnect the hose.
Installation Notice
2. Unscrew the mounting bolts and remove the brake caliper
assembly.
Installation Notice
3. Pull out the brake pads. Replace pads if necessary.
Notice
Always change the all pads on one wheel at a time.
4. Installation should follow the removal precedure in the
reverse order.
5. Bleed the air from the system.

5B-6 MANUAL TRANSMISSION
Check
Loosened transmission or flywheel housing bolts,
improper alignment.
Synchronizer damaged or excessively worn.
Blocking ring damaged, worn index slots or friction
surfaces worn or damaged.
Excessive countershaft end play.
Worn or damaged fork due to loosened shaft, rail or
shifting fork.
TRANSMISSION JUMPS OUT
Action
Tighten bolts to specified value. Realign if necessary.
Check or replace synchronizer parts.
Check or replace blocking ring.
Check worn or damaged parts. Adjust shim thickness
using roller bearings if necessary.
Check for wear or damaged. Replace worn or
damaged parts.
Check
Fork or offset lever loose on shaft or rail.
Worn or damaged forks, offset lever, shaft or rail.
Worn or damaged synchronizer.
Worn or damaged gears.
TRANSMISSION LOCKED IN ONE GEAR
Action
Replace extension, adapter or case cover. Check or
replace loose parts on shaft or rail. Replace roll pin(s).
Remove extension, adapter or case cover. Check for
wear or damaged. Replace damaged parts.
Check worn or damaged synchronizer parts and
replace if necessary.
Check worn or damaged gears and replace if neces-
sary.
Check
Improper or low transmission oil.
Loose bolts or other attaching parts.
Improper flywheel housing to engine crankshaft
alignment.
Noisy transmission bearing.
Noisy gears.
TRANSMISSION NOISE
Action
Add or drain and replace with proper oil.
Tighten as specified.
Realign correctly.
Check bearings, bearing rollers and parts for wear or
damage.
Replace if necessary.
Check for worn or damaged gears
(including speedometer gear).
Replace if necessary.

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.

TRANSFER CASE (PART TIME 4408) 5D1-3
Cannot Front Wheel Drive when Shifted 4H,4L
DIAGNOSIS
Electric Shift Problems
Action
Overhaul and check, replace if necessary.
Overhaul and check for wear and damage.
Replace if necessary.
Check sliding parts, replace if necessary. Checks
Faulty or Damaged TCCU, Speed Sensor, Motor, Clutch
or Internal Wirings
Damaged or Worn Shift Cam, Hub, Fork and Rail Shift
Binding Shift Fork, Hub Collar or Gear
Checks
Broken Drive ChainAction
Check sliding parts, replace if necessary.
Noise in 4WD Operation
Checks
Improper or low oil
Loosened bolts or mounted parts
Noisy T/C bearing
Noisy gearsAction
Drain and replace with specified oil.
Retighten as specified.
Disassemble bearings and parts and check for wear or
damage. Replace if necessary.
Check for wear and damage including speedometer
gear, replace if necessary.
Noise in 4H or 4L
Checks
Worn or Damaged Sprockets or Drive Chain
Incorrect Tire PressureAction
Disassemble and check for wear and damage, replace
if necessary.
Adjust tire pressure.
Transfer Case Oil Leakage
Action
Replace the case.
Clean case and parts and check for leakage.
Remove breather hose and clean, replace if necessary.
Use specified oil and adjust oil level.
Retighten
Use specified sealant and retighten.
Replace Checks
Cracked Transfer Case
Leakage from Other Parts
Breather Clogging
Improper or too much Oil
Loosened Sealing Bolts
Improperly Applied Sealant
Worn or Damaged Oil Seal

5D2-44 TRANSFER CASE (TOD)
9. Remove the bolts that retain the front case to the
rear case. Make sure that the front case is facing
downward so that the rear cover is facing upwards.
Pry on the bosses and separate the front case from
the rear case. Remove all traces of gasket sealant
from the mating surfaces of the front case and rear
case.
10. If the speedometer drive gear is to be replaced, first
remove the flange seal by prying and pulling the
curved-up lip of the flange seal. Do not damage the
bearing, bearing cage or case. Remove and discard
the flange seal. Remove the speedometer drive gear
and upper tone wheel.
69 Yoke to Flange Seal
75 Snap Ring
76 Bearing
77 Speedometer Drive Gear
79 Upper Tone Wheel
40 Clutch Coil
40a Clutch Coil Retaining Bolts
40b Wire
11. If the rear output shaft bearing requires replacing, remove
the internal snap ring that retains the bearing in the bore.
From the outside of the case, drive out the bearing.
12. Remove the three nuts and washers retaining the clutch
coil assembly to the rear case. Pull the assembly, along
with the O-ring and wire, from the case.
13. Remove bearing assembly from output shaft.
Remove the clutch housing from the output shaft.
Remove the balls and apply cam and wave washer from
the output shaft.
Remove snap ring from output shaft. Remove clutch pack
assembly from output shaft.
25 Ball
26 Cam and Coil Assembly

TRANSFER CASE (TOD) 5D2-51
25. Install the pin on the tang end of the helical cam into the
hole in the front case. Position the torsion spring tangs so
that they are pointing toward the top side of the transfer
case and just touching the high-low shift fork.
CAUTION
Do not bend the helical cam during installation to the front
case because of possible damage to the pin at the tang
end of the motor shaft.
26. Install the shift rail through the high-low shift fork and make
sure that the reverse gear shift rail is seated in the front
case bore.
27. Install upper and lower speed sensors into the cover. Feed
the coil wire through the upper speed sensor wire shield.
28. Install upper tone wheel, speedometer gear and rear output
seal. Use Output Shaft Seal Replacer and Driver or
equivalent to install seal.
29. Coat the mating surface of the front case with a bead of
Black Non-Acid Cure Silicone Rubber or equivalent.
30. The following procedure must be followed prior to installing
the rear case onto the front case half:
a. Align the output shaft with the rear case output shaft bore.
b. Align the helical cam with the rear case motor bore.
If difficulty is encountered with seating the rear case, tap
the rear output shaft with a sharp blow using a rubber
mallet in a direction away from the triangular shaft while
pushing down on the rear case.
Tightening Torque 25 - 37 Nm 31. Install the bolts retaining the case halves and tighten.

6A-2 POWER STEERING SYSTEM
Checks
Damaged or Binding Steering Ball Joint
Improper Preload of Steering Pinion
Damaged Wheel or Tire
Faulty Suspension SystemChecks
Worn Steering Gear
Worn or Damaged Steering Ball Joint
Loosened Steering Gearbox BoltsChecks
Damaged Steering Linkage
Damaged Wheel and Tire
Faulty Brake System
Faulty Suspension SystemChecks
Lack of Lubrication
Abnormal Wear or Binding of Steering Ball Joint
Damaged or Faulty Steering Gear
Improper Preload of Steering Pinion
Faulty Steering Shaft Joint
Steering Fluid Leaks
Lack of Fluid or Air-in System
Faulty Steering Oil Pump
Damaged or Loosened Pump Drive Belt
Clogging Oil Line
Damaged Wheel or Tire
Faulty Suspension System
DIAGNOSIS
HARD STEERING
Action
Lubricate
Replace
Replace gear assembly
Adjust
Replace
Repair or replace
Replenish or bleed
Replace
Adjust or replace
Repair or replace
Repair or replace
Repair or replace
STEERING PULLS TO ONE SIDE
Action
Repair
Repair or replace
Repair or replace
Repair or replace
EXCESSIVE WHEEL PLAY
Action
Replace gear assembly
Replace
Retighten
POOR RETURN OF STEERING WHEEL
Action
Replace
Replace gear assembly
Repair or replace
Repair or replace

6E-4 STEERING WHEEL AND COLUMN
6. Disconnect each connectors.
7. Remove the vacuum hose from the ignition switch(Diesel
only) .
9. Remove the lower shaft by removing the bolt of the steering
column shaft.
Installation Notice
Tightening Torque 9 - 14 Nm
8. Remove the combination switch assembly.
10. Remove the dash panel mounting bolts.
Installation Notice
Tightening Torque 30 - 40 Nm