clutch SSANGYONG MUSSO 2003 Owners Manual

MANUAL TRANSMISSION 5B-5
Check
Clutch not releasing. Improper or low transmission oil. Shift or shift rail binding. Binding of sliding synchronizers or gears.
If reverse only, faulty backup switch. Worn or damaged flywheel pilot bushing. Check
Control lever assembly broken or damaged.
Damaged offset lever, shift fork, selector place or selector arm. DIAGNOSIS
WILL NOT SHIFT(CONTROL LEVER MOVES)
Action
Replace control lever and housing assembly.
Remove extension, adapter or case cover. Check or replace damaged parts.
HARD SHIFT OR CONTROL LEVER WILL NOT MOVE INTO GEAR
Action
Adjust or replace clutch. Add or replace with specified oil.
Remove extension, adapter or case cover. Check or replace damaged parts.
Remove extension, adapter or case cover. Check synchronizers and gears and replace damaged parts. Check or replace backup switch. Replace pilot bushing.
GEARS CRASH WHEN SHIFTING
Check
Engine idle speed too high. Damaged or faulty clutch.Pilot bearing between input shaft and output shaft binding.
Damaged synchronizer. Bell housing misaligned. Damaged gear(s).Worn or damaged flywheel pilot bushing. Action
Adjust idle speed to specified speed.Adjust or replace clutch.Replace or check roller bearings.Check or replace synchronizer parts. Align bell housing and bore. Check or replace gear(s).Replace pilot bushing.

5B-8 MANUAL TRANSMISSION1 Shift Hop-out 2 Shift Gear Crash 3 Shift Block-out 4 Hard Shift 5 Noise in Reverse Gear6 Noise in 5th Gear 7 Noise in 4th Gear 8 Noise in 3rd Gear 9 Noise in 2nd Gear 10 Noise in 1st Gear
11 Noise in All Speeds 12 Leak at Transmission Rear Part 13 Leak at Transmission Center Part 14 Leak at Transmission Front
DIAGNOSIS TABLE
Condition
Possible Faulty Part
Transmission Case Extension HousingShift Cover / Shift ShiftShift Control LeverInput Bearing RetainerInput Gear Set3rd Speed Gear Set2nd Speed Gear SetReverse Speed Gear Set1st Speed Gear Set5th Speed Gear SetClutch Housing and Release DeriveCrankshaft Pilot Bushing and Release BearingInput BearingMain Shaft Input BearingMain Shaft Thrust Bearing3rd Speed Gear Bearing2nd Speed Gear Bearing1st Speed Gear BearingReverse Idler Gear BushingCounter Shaft Front BearingCounter Shaft Rear BearingCounter Shaft Thrust Bearing5th Speed Drive Gear Bearing
Slip Yoke Bushing
Slip Yoke SealSpeedometer Drive / Driven GearsSpeedometer Driven Gear HousingInput Shaft Seal1 - 2 Synchronizer Assembly3 - 4 Synchronizer Assembly5th Synchronizer AssemblyRing Oil SealT/C Front Face

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
15 Bolt ...................................................... 70-80 Nm
16 Cross Member
17 Washer
18 Bolt ...................................................... 21-35 Nm
19 Washer
20 Bolt ...................................................... 62-93 Nm
21 Breather Hose

5B-42 MANUAL TRANSMISSION
6. Check the following Bearing for excessive war: Crankshaft pilot bushing for the front of the input shaft.
Clutch release bearing.
Input shaft bearing.
Main shaft pilot bearing rollers.
Main shaft thrust Bearing and its surfaces.
Speed gear roller bearing on the main shaft.
Main shaft rear bearing.
Counter shaft front and rear bearings.
7. Check the gear tooth surfaces of all gear sets.
8. Check the reverse gear set surfaces. Check the surfaces of gear teeth for excessive wear, pitting, scoring and spalling
and replace if necessary.

MANUAL TRANSMISSION 5B-43
9. Take apart the three synchronizer assemblies and check : The 1-2 synchronizer.
The 5th blocking ring.
10. Check the fit between the hub and sleeve of each synchronizer
Excessively tight or loose hub-to-sleeve fit.
Wear of the cone clutch surfaces of brass blocking rings and gears.
11. Measure the clearance between the blocking ring and the speed gear
New 1-2 blocking ring : 0.87-1.4mm
New 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.

5B-44 MANUAL TRANSMISSION
12. Check for gear clash on the synchronizer sleeve teeth orthe clutch teeth on the speed gear.
13. Check the synchronizer sleeve and gear clutch tooth for hop-out.

MANUAL TRANSMISSION 5B-45
PRE-INSTALLATION CHECKS Checking Procedure
1. Separate the clutch release fork from the pivot and removethe pivot from the clutch housing.
2. Check the pivot. Fork and release bearing.
3. Check the pressure plate spring. Notice Inspect each parts and replace the excessively worn parts.
4. Check the clutch housing alignment as follows : Place the magnetic base on the pressure plate spring.
Check the housing bore alignment.
- Place the dial indicator on the bore.
- By rotating the crankshaft one revolution, record the
dial indicator reading.

5B-46 MANUAL TRANSMISSION
Check the housing face alignment.
- Place the dial indicator on the housing face.
- By rotating the crankshaft one revolution, record the
dial indicator reading.
NoticeIf the reading is greater than 0.010 inch, insert the shim between the engine and clutch housing and adjust thealignment.
5. Check the following parts : Pressure plate spring assembly
Disc
Flywheel
Input shaft pilot bearing
Notice
Replace the excessively worn parts.
6. Lubricate the clutch release bearing bore, fork pivot head during assembly.

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
15.87 mm
14.0 mm
17.46 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 thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
Application
Type Max. Pedal StrokePedal Free Play
TypeThickness of Disc Stroke Inner DiameterStrokeInner 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

5C-2 CLUTCHFASTENER TIGHTENING SPECIFICATIONS
Application
Clutch Cover Bolt Clutch Housing Bolt Clutch Release CylinderMaster Cylinder Nut
Clutch Tube NutPedal Push Rod Nut Pedal Mounting
N 

 m
37 47
30 - 40 8 - 18
15 - 18 16 - 22
8 - 18
21 - 25
Bracket Bolt Stopper Bolt