SSANGYONG MUSSO 2003 Service Manual

5C-6 CLUTCH
COMPONENT LOCATOR
CLUTCH ASSEMBLY
1 Clutch Disc
2 Clutch Cover
3 Clutch Housing
4 Release Bearing
5 Release Fork Pivot
6 Release Cylinder
7 Release Fork Boot 8 Bolt
9 Release Fork
10 Bolt 11 Spring Lock Washer
12 Transmission Input Spline
13 Release Bearing Contacting Surface
14 Contacting Point of Release Fork and Pivot
Notice
Apply the long-term grease (DBL 6811.00) to No.12,13 and 14.

CLUTCH 5C-7
PEDAL AND MASTER CYLINDER
1 Clutch Pedal
2 Clutch Master Cylinder
3 Clutch Tube
4 Clutch Oil Chamber5 Clutch Tube
6 Clutch Hose
7 Clutch Release Cylinder

5C-8 CLUTCH
MAINTENANCE AND REPAIR ON-VEHICLE SERVICE BLEEDING OF CLUTCH SYSTEM Bleeding procedure Notice Keep the fluid level over ‘MAX ’ in reservoir during
bleeding operation.Do not let fluid contact a painted surface.
1. Remove the air bolt cap of the release cylinder.
Connect a vinyl tube to the bolt.
2. Insert the other end of the tube in a vacant container.
3. Slowly depress the clutch pedal several times.
4. With clutch pedal fully depressed, open the air bolt and release air rind fluid in the fluid line,
5. Repeat this procedure until there are no more air bubbles in the fluid flows.

CLUTCH 5C-9
CLUTCH DISC Preceding Work : Removal of the transmission
1 Clutch Disc
2 Clutch Cover Assembly
3 Release Bearing
4 Clutch Housing
Tools 602 589 00 40 00 Engine Lock661 589 00 15 00 Centering Pin 5 Washer
6 Bolt
........................................................... 23 Nm
7 Washer
8 Bolt ........................................................... 44 Nm

5C-10 CLUTCH Removal & Installation Procedure
1. Remove the starter motor. Install the special tool to theflywheel 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. NoticeBe 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
Before installation, clean oil and grease on the flywheel surface.
Do not clean the clutch disc and release bearing insolvent.

5C-12 CLUTCH
Inspection Procedure
1. Clutch Cover Check the diaphragm spring tip for wear and height
unevenness.
Check the pressure plate surface for wear, crack and
discoloration.
Check the strap plate rivet for looseness and replace
the clutch cover if loosened.
Unevenness Limit 0.8 mm
2. Clutch Disc Check the facing for rivet looseness, excessive runout,
sticks, oil and grease.
Measure the rivet head depth. If out limit, replace the disc.
3. Clutch Release Bearing The release bearing is permanently lubricated and
requires no cleaning.
Check the bearing for sticks, damage, abnormal noise,
turning drag and wear.
4. Release Fork If there is abnormal wear in contact point with bearing,
replace the release fork.
Wear Limit 0.3 mm

CLUTCH 5C-13
MASTER CYLINDER
1 Snap Pin
2 Clevis Pin
3 Clevis
4 Lock Nut
5 Flange Nut ........................................... 30-40 Nm
6 Push Rod
7 Cylinder Body
8 Oil Pipe ................................................ 15-18 Nm 9 Clamp
10 Reservoir
11 Spring
12 Piston Assembly
13 Boot
14 Plate
15 Snap Ring
Notice Do not disassemble the No.12.

5C-14 CLUTCH
Removal & Installation Procedure
1. Draw out the fluid.
2. Pull out the snap pin and clevis pin from the clutch pedalconnection.
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.

CLUTCH 5C-15
CLUTCH PEDAL
1 Snap Pin................................................ Replace
2 Clevis Pin ...................................... Apply Grease
3 Master Cylinder Push Rod
4 Gasket
5 Nut ....................................................... 16-22 Nm
6 Spring washer
7 Bolt ........................................................ 8-18 Nm
8 Fulcrum Pin 9 Turn Over Spring
..........................Apply Grease
10 Bushing ......................... Replace, Apply Grease
11 Full Stroke Stopper Contact Pad
12 Clutch Pedal
13 Pedal Pad
14 Pedal Mounting Bracket
15 Stopper Bolt .......................................... 21-25Nm
16 Clutch Interlock Switch
Notice
Assembly should follow the disassembly procedure in the reverse order.
Grease specification : Long - term grease (T/Mn DBL6611.00)