drain bolt SSANGYONG MUSSO 1998 Workshop Service Manual

REAR DRIVE AXLE 3D-11
UNIT REPAIR
AXLE HOUSING
Preceding Work : Removal of the axle shaft
Removal of the axle housing
1 Drive Pinion Lock Nut......................240-310 Nm
2 Washer
3 Companion Flange
4 Pinion Oil Seal
5 Bearing Slinger
6 Bearing
7 Shim
8 Shim
9 Bearing Cup
10 Breather Nipple
11 Rear Axle Housing
12 Oil Drain Plug.......................................28-42 Nm
1 3 Shim
14 Bearing
15 Drive Pinion
16 Bearing Cap1 7 Bolt....................................................87-124 Nm
18 Bearing
1 9 Shim
20 Ring Gear
21 Shaft Lock Pin
22 Differential Case
23 Ring Gear Mounting Bolt......................75-90 Nm
24 Thrust Washer
25 Differential Pinion
26 Thrust Washer
27 Side Gear
28 Differential Shaft
29 Housing Cover
3 0 Bolt......................................................38-46 Nm
31 Oil Filler Plug.......................................28-42 Nm

3D-12 REAR DRIVE AXLE
Disassembly Procedure
1. Remove the drain plug and drain the oil. Reinstall the drain
plug.
2. Remove the axle housing cover.
Notice
Clean the cover and housing contact surface.
3. Remove the bearing cap bolts and remove the bearing caps.
Pull out the differential carrier assembly.
Notice
Place alignment marks on the bearing cap not to change
the caps before removal. When pulling out the differential
carrier assembly, be careful not to damage the axle housing.
4. Disassemble the parts of the differential carrier assembly.
Tightening Torque 28 - 42Nm

5B-2 MANUAL TRANSMISSION
FASTENER TIGHTENING SPECIFICATIONS
Application
Transmission
Oil Filler Plug
Transmission Mounting Bolt (Housing)
Oil Drain Plug
Front Propeller Shaft (T/C)
Rear Propeller Shaft (T/C)
Cross Member Bolt (Center)
Cross Member Bolt (Side)
Control Cable
Shift Lever BoltNlm
25
77 - 87
25
81 - 89
70 - 90
21 - 35
62 - 93
20 - 30

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.

5B-10 MANUAL TRANSMISSION
1 Filler/Drain Plug
2 Shift Mechanism Cover
3 Shift Shaft Lever
4 Outer Select Lever
5 Inner Select Lever
6 Offset Control Lever
7 Bias Spring
8 Bolt
9 Pin
10 Washer
11 Bolt
1 2 Bolt
13 Extension and Plate Assembly
14 O-Ring & Steel Ring
15 Oiling Funnel
1 6 Bolt
17 Alignment Bolt
18 Pin
19 Shift Shaft
20 3/4 Shift Fork
21 1/2 Shift Fork
22 Insert
23 Selector Arm Assembly
24 Interlock Plate Assembly
25 Selector Plate
26 O-ring
2 7 Plug
28 Case Cover
29 Retaining Ring
30 Pivot Pin
31 Back-up Switch
32 5/Reverse Shift Lever
33 Snap Ring
34 5th Synchronizer Retainer
35 5th Synchronizer Assembly
36 Synchronizer Spring
37 Synchronizer Assembly38 Insert
39 Synchronizer Hub
40 Roll Pin
41 5th Shift Fork
42 Insert
43 Shift Rail Assembly
44 Blocking Ring
45 5th Speed Drive Gear
46 Snap Ring
47 Speed Gear
48 Speed Gear Clip
4 9 Bolt
50 Input Bearing Retainer
51 Oil Seal
5 2 Shim
53 Bearing Cup
54 Bearing Cone
55 Input Shaft
56 Roller Bearing
57 Spacer
58 Thrust Bearing
59 Thrust Bearing Race
60 5th Speed Driven Gear
61 Bearing Cup
62 Bearing Cone
63 1st Speed Gear
64 Bearing Sleeve Assembly
65 A. Bearing
65 B. Bearing
65 C. Spacer
66 Sleeve
67 Blocking Ring Assembly
68 3/4 synchronizer Assembly
69 Synchronizer Spring
70 Synchronizer Sleeve
71 Insert
72 Synchronizer Sleeve73 3rd Speed Gear
74 Needle Bearing
75 Spacer
76 Snap Ring
77 Thrust Washer
78 2nd Speed Gear
79 2nd Speed Gear Bearing
80 Spacer
81 Output Shaft Assembly
82 Retaining Ring
83 Thrust Washer
84 Inner Cone
85 Outer Cone Race
86 1/2 Blocking Ring
87 Spring Gear
88 Reverse Sliding Gear
89 Insert Gear
90 Pin
91 Shaft and Hub Assembly
92 Spring
93 Pin Fork and Reverse Roller
Assembly
9 4 Bolt
95 Rear Bearing Retainer
9 6 Shim
97 Roll Pin
98 Reverse Idler Shaft
99 Reverse Idler Gear Assembly
100 O-ring
101 Bearing Cup
102 Bearing Cup Assembly
103 O-ring
104 Bearing Cup
105 Bearing Cone
106 Counter Shaft Gear
107 Transmission Case Assembly

5B-14 MANUAL TRANSMISSION
TRANSMISSION
Preceding Work : Removal of the shift control cable
1 Clutch Housing
2 Oil Filler Plug............................................ 25 Nm
3 Transmission Assembly
4 Back-up Switch
5 Washer
6 Bolt......................................................77-87 Nm
7 Oil Drain Plug............................................ 25 Nm
8 Bolt......................................................81-89 Nm
9 Washer
10 Front Propeller Shaft
11 Transfer Case Assembly12 Speedometer Cable
13 Rear Propeller Shaft
14 Washer
1 5 Bolt......................................................70-80 Nm
16 Cross Member
17 Washer
1 8 Bolt......................................................21-35 Nm
19 Washer
2 0 Bolt......................................................62-93 Nm
21 Breather Hose

MANUAL TRANSMISSION 5B-17
UNIT REPAIR
MAJOR UNIT
Preceding Work : Removal of the transmission
Removal of the transfer case
Disassembly Procedure
1. Install the removed transmission into a fixture.
2. Remove the drain plug and drain the oil. Using a 13 mm
wrench, remove the clamp bolt and position the offset lever
in the 3-4 position of neutral.
Notice
Removal of the offset lever in a position other than 3-4 of
neutral will be difficult.
3. Using a pin punch and a hammer, remove the roll pin to
remove the shift lever from the offset lever.
4 . Using a 15 mm wrench, remove the 8 bolts from the extension
housing.
5. Separate the extension housing from the case and shift
cover.
Separate the offset lever from the shift.
Notice
Do not remove the offset lever while the extension housing
is still assembled to the case.
6. Remove the offset lever from the extension housing with
the detent ball and spring.
7. Remove the roll pin from either the offset lever or extension
housing.

5B-18 MANUAL TRANSMISSION
8. Remove the counter shaft thrust race and bearing.
9. Carefully remove the oiling funnel from the end of the
counter shaft.
10. Using a 10 mm wrench, remove the 10 bolts from the shift
cover.
Notice
For assembly, note the location of the two bolts.
11. Lift up the shift cover after sliding it toward the drain plug
about 3 cm. At this time remove sealer bond.
12. Using a needle nose pliers, remove the 5-R lever clip.

5B-26 MANUAL TRANSMISSION
21. Completely compress the detent spring.
22. To install the extension housing to the case, apply sealer
to the top two bolts and tighten them and tighten the 6
bolts.
23. Apply sealer to the back-up lamp switch and drain plug
and tighten them.
24. Using a hammer, install the offset lever-to-shift roll pin.
25. Turn the transmission case reversely and place a dial
indicator on the extension housing. Move the input and
main shift up and down and measure end play. Select a
shim which is the same thickness as the measurement (±
0.001 inch). After shim installation, the end play should be
‘0’.
26. Remove the input bearing retainer and do the following :
lInstall the adjusting shim behind the input bearing outer
race in the retainer and if 2 shims are used, install the
thinner one in first.
lInstall the retainer to the case and tighten the bolts.
lIf end play is not ‘0’change the shim again.
lApply RTV sealant to the sealing surface of the retainer.
lApply sealer to the 4 retainer bolts and tighten them.
27. Remove the fill plug.
28. Remove the transmission from the holding fixture and install
it to the vehicle.
29. Clean the sealing surface of the shift control lever.
30. Install the control cables to the shift lever.

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