drain bolt SSANGYONG MUSSO 2003 Workshop Manual

3D-12 REAR DRIVE AXLE
Disassembly Procedure
1. Remove the drain plug and drain the oil. Reinstall the drainplug.
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 TRANSMISSIONFASTENER TIGHTENING SPECIFICATIONS
Application
Transmission
Oil Filler Plug
Transmission Mounting Bolt (Housing) Oil Drain PlugFront Propeller Shaft (T/C)Rear Propeller Shaft (T/C)Cross Member Bolt (Center) Cross Member Bolt (Side)
Control Cable Shift Lever Bolt
Nm
25
77 - 87 25
81 - 89 70 - 9021 - 3562 - 93 20 - 30

5B-6 MANUAL TRANSMISSIONCheck
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 GEARAction
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 forwear 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 crankshaftalignment.Noisy transmission bearing. Noisy gears. TRANSMISSION NOISEAction
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 TRANSMISSION1 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
12 Bolt
13 Extension and Plate Assembly
14 O-Ring & Steel Ring
15 Oiling Funnel
16 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
27 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 Assembly 38 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
49 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 Sleeve 73 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
94 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
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-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.

5B-26 MANUAL TRANSMISSION
21. Completely compress the detent spring.
22. To install the extension housing to the case, apply sealerto 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 : Install the adjusting shim behind the input bearing outer
race in the retainer and if 2 shims are used, install thethinner one in first.
Install the retainer to the case and tighten the bolts.
If end play is not ‘0’change the shim again.
Apply RTV sealant to the sealing surface of the retainer.
Apply 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,4LDIAGNOSIS
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 Chain Action
Check sliding parts, replace if necessary.
Noise in 4WD Operation
Checks
Improper or low oil Loosened bolts or mounted partsNoisy T/C bearing Noisy gears Action
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 Pressure Action
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 CaseLeakage from Other PartsBreather CloggingImproper or too much OilLoosened Sealing Bolts Improperly Applied Sealant Worn or Damaged Oil Seal

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
Rear 81 - 89 Nm 70 - 80 NmTightening Torque