SSANGYONG MUSSO 2003 Service Manual

5B-12 MANUAL TRANSMISSION
Removal & Installation Procedure
1. Position the shift lever in neutral and remove the knob.
2. Remove the screw from the console box side and removethe shift lever cover.
3. Disconnect the cables by removing the snap pins from the control cable connections to the select lever and shift lever.
4. Remove the shift lever an cable mounting snap pin and
washer of the select lever.

MANUAL TRANSMISSION 5B-13
5. Pull out the clip from the bracket and remove the shift cableand select cable.
6. Installation is reverse order of the removal. Inspection Procedure
1. The shift lever should be positioned in neutral.
2. Apply liquid gasket on the cable contact surface.
3. Keep 130 mm between the center of the cable end-eye and floor. Notice
If necessary, adjust the adjust nut.
Standard 130 mm

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

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 anddrain 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 thetransfercase. Installation Notice
Tightening Torque 81 - 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 Nm62 - 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-17
UNIT REPAIR MAJOR UNIT Preceding Work : Removal of the transmissionRemoval 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. NoticeRemoval 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.NoticeDo 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 thecounter 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.

MANUAL TRANSMISSION 5B-19
13. Using a 21 mm wrench or a T-50 bit, remove the 5-R leverpivot bolt. Notice
Apply sealer bond to this bolt during assembly.
14. Using a 22 mm wrench, remove the back-up lamp switch from the 5-R lever side.Notice Apply sealer to the threads.
15. Pull out the 5-R lever out of the transmission.
16. Using a snap ring pliers, remove the 5th synchronizer snap ring from the end of the counter shaft.
17. Remove the 5th synchronizer assembly with its fork and rail assembly from the counter shaft.

5B-20 MANUAL TRANSMISSION
18. Remove the slip yoke snap ring from the main shaft.
19. Remove the 5th speed drive gear snap ring from the mainshaft.
20. Make alignment marks on the case and input bearing retainer and remove the 4 input shaft bearing retainer bolts, using a 13 mm wrench. Notice
Apply sealer on these bolts during assembly.Remove the input bearing retainer with the bearing outer race and shim.
21. Remove the input shaft from the case by rotating it until the flat surface appears.
22. Remove the following parts from the input shaft. 4th speed gear blocking ring.
Main shaft thrust race and bearing.
Main shaft pilot bearing rollers (15 rollers).
Notice Be careful not to dissipate the pilot bearing rollers.

MANUAL TRANSMISSION 5B-21
23. Remove the main shaft in 2 steps.To remove the rear bearing outer race, push the main
shaft rearward.
Tilt and lift the main shaft from the case.
24. Remove the reverse fork and spring from the case.
25. Remove the counter shaft as follows: Using a punch and hammer, pry up the lock tabs.
Using a 13 mm wrench or T-40 bit, remove the 4 bolts.
Remove the retainer and shim from the case.
Push the counter shaft rearward to remove the rear
bearing outer race.