torque SSANGYONG MUSSO 1998 Workshop Repair Manual

AUTOMATIC TRANSMISSION 5A-127
Torque Converter and Housing Assembly
To assemble the torque converter and housing assembly,
proceed as follows.
1. Locate the torque converter housing on the transmission
main case.
2. Install and tighten the securing bolts to specification.
Notice
All the hardware must be correctly installed and torqued to
specification.
3. Fit the converter ensuring that the tangs are engaged in
the pump gear. Ensure that the tangs do not contact the
pump seal.
Figure 8.1 - Torque Specifications
Torque Specifications
Torque converter housing to case
Extension housing to case
Rear servo cover
Pan to case
Inhibitor switch to case
Cooler connectors
Transmission filler plug
Output flange lock nut (RWD models)
Centre support to case
Cam plate to case (parking pawl)
Valve body to case
Upper valve body to lower valve body
ON/OFF solenoid retainers
Variable pressure solenoid retainer
Line pressure plug
Detent spring
Pump cover to case
Pump cover plate to pump cover
Pump to pump adaptor
Pump cover plate to crescent
Adaptor to caseNlm
54 - 68
54 - 68
25 - 35
4 - 6
2.3 - 3.4
30 - 35
30 - 35
100 - 110
20 - 27
16 - 22
8 - 13
11 - 16
8 - 12
8 - 12
4 - 7
20 - 22
24 - 34
13 - 16
24 - 27
13 - 16
25 - 35

MANUAL TRANSMISSION 5B-15
Removal & Installation Procedure
1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the drain plug from the transmission housing and
drain the oil. Reinstall the drain plug.
Installation Notice
Tightening Torque
25 Nm
4. Disconnect the back-up switch connector.
5. Remove the breather hose.
6. Remove the speedometer connector and other wiring
harnesses and connectors.

5B-16 MANUAL TRANSMISSION
7. Remove the front and rear propeller shafts from the
transfercase.
Installation Notice
Tightening Torque81 - 89 Nm
70 - 90 NmFront
Rear
8. Support the transmission on an suitable jack.
Unscrew the center mounting nuts and each sides
mounting bolts and remove the cross member.
Installation Notice
9. Remove the transmission mounting bolts.
Installation Notice
Tightening Torque (1)
Tightening Torque (2)21 - 35 Nm
62 - 93 Nm
10. Move the transmission jack backward careful and
disengage the transmission input shaft from the engine.
Remove the transmission.
11. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 77 - 87 Nm

MANUAL TRANSMISSION 5B-23
Assembly Procedure
1. Using a hydraulic press and a supporting tool, press the
counter shaft rear bearing into the case. Be sure that the
supporting tool inside of the case should support the counter
shaft.
2. Without the shim, install the retainer and counter shaft rear
bearing outer race. Tighten the 4 retainer bolts.
3. Place a dial indicator on the case and measure counter
shaft end play by moving up and down.
4. Select a shim which is the same thickness as the indicator
rearing (up to 0.004 inch) and assemble it.
5. When the end play is correctly adjusted, remove the counter
shaft rear bearing retainer and outer race.
6. Using a pin punch and rubber hammer, install the reverse
idler shaft, gear and O-ring.
Tightening Torque 20 Nm

5B-24 MANUAL TRANSMISSION
7. Install the counter shaft rear bearing outer race, shim and
retainer.
Tightening Torque
39 - 52 Nm
lUsing a punch and hammer, bend the lock tabs on the
retainer.
8. Install the following parts :
lInstall the main shaft into case.
lInstall the main shaft rear bearing outer race into the
rear of the case.
lInstall the 4th speed blocking ring onto the front of the
main shaft.
lInstall the input shaft onto the front of the main shaft.
lInstall the input bearing retainer without shim onto the
front of the case.
lUsing a torque wrench, tighten the 4 bolts.
9. Install the 5th speed drive gear and blocking ring on the
counter shaft.
10. Install the 5th synchronizer and rail/fork.
11. Install the 5th synchronizer snap ring and oiling funnel.
12. Align the slots of the lever with the rollers of the reverse
fork and 5th shift rail. Apply sealer on the 5-R lever pivot
bolt and install it into the case.
Tightening Torque 28 Nm
13. Using a needle nose pliers, install the 5-R lever clip.

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-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.

5D1-10 TRANSFER CASE (PART TIME 4408)
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
MAINTENANCE OF TRANSFER CASE
LUBRICANT
Oil Level Check
lClean the oil level plug and surrounding area.
lRemove the oil level plug and check whether oil is drip
out or not.
lTighten the oil level plug.
Oil Change
lClean the oil level plug and surrounding area
lPlace a suitable container under the transfer case.
lRemove the oil and tighten the drain plug.
lFill the oil through the oil level plug until oil begins to
drip out.
lTighten the oil level plug.
Cautions for oil level check and plugs tightening
lDo not use an impact wrench to remove or tighten the
oil level plug or drain plug since this will damage the
threads in the transfer case.
Tightening Torque 20 - 30 Nm

5D1-12 TRANSFER CASE (PART TIME 4408)
Removal & Installation Procedure
1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the drain plug and drain the oil.
Reinstall the drain plug.
* If planar damper is installed, unscrew 4 bolts and remove
the planar damper.
Installation Notice
Tightening Torque 19 - 30 Nm
4. Remove the breather hose.
5. Disconnect the speedometer cable connector and other
cable connectors and wiring harnesses.
6. Support the transfer case with jack and remove the front
and rear propeller shafts from the transfer case.
Installation Notice
Front
Rear81 - 89 Nm
70 - 80 NmTightening Torque