Page 1353 of 2053
MANUAL TRANSMISSION 5B-45
SSANGYONG MY2002
YAD5B1C0
INSPECTION OF COMPONENTS
Inspection Procedure
1. Clean all parts with solvent and dry them with
compressed air. Check the following parts for
cracks and damaged sealing surfaces.
Case
Extension housing
Shift Cover
Input bearing retainer
Counter shaft rear bearing retainer
2. Check the parts which support bearings and shafts
for excessive wear and replace them if necessary.
YAD5B1D0
YAD5B1B0
3. Check the bearing surfaces of the following parts ;
Input shaft
Main shaft and its gears
Counter shaft and 5th drive gear
4. Check the reverse idler shaft and its gears.
Notice: Replace excessive wear parts and do not
file on the hardened surface and precision ground.
5. Check the shift mechanism parts as follows :
Wear of the shift shaft.
Wear of the detent/guide plate and offset lever.
YAD5B1E0
Page 1354 of 2053
SSANGYONG MY2002
5B-46 MANUAL TRANSMISSION
8. 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.
YAD5B1J0
YAD5B1F0
YAD5B1H0
YAD5B1G0
6. Check worn edges on the following parts :
Selector arm.
Interlock plate.
Selector plates for the 1-2 and 3-4 shift forks.
5-R shift lever and the rollers on the reverse
fork and the 5th shift rail/fork.
7. Check worn mating surfaces on the following parts :
1-2 shift fork, pads and synchronizer sleeve.
3-4 shift fork, pads and synchronizer sleeve.
5th shift rail/fork pads and synchronizer sleeve.
Reverse fork and reverse idler gear sleeve.
Page 1355 of 2053
MANUAL TRANSMISSION 5B-47
SSANGYONG MY2002
YAD5B1K0
YAD5B1M0
Speed gear roller bearing on the main shaft.
Main shaft rear bearing.
Counter shaft front and rear bearings.
YAD5B1L0
9. Check the gear tooth surfaces of all gear sets.
10. Check the reverse gear set surfaces. Check the
surfaces of gear teeth for excessive wear, pitting,
scoring and spalling and replace if necessary.
11. Take apart the three synchronizer assemblies and
check :
The 1-2 synchronizer.
YAD5B1N0
Page 1356 of 2053
SSANGYONG MY2002
5B-48 MANUAL TRANSMISSION
14. Check for gear clash on the synchronizer sleeve
teeth or the clutch teeth on the speed gear.
15. Check the synchronizer sleeve and gear clutch
tooth for hop-out.
YAD5B1S0
YAD5B1P0
YAD5B1R0
YAD5B1Q0
The 5th blocking ring.
12. 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.
13. 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.
Page 1357 of 2053

Specifications.......................................................5C-2
General Specifications.........................................5C-2
Fastener Tightening Specifications.......................5C-2
Component Locator.............................................5C-3
Clutch Assembly.................................................5C-3
Pedal and Master Cylinder...................................5C-4
Maintenance and Repair.....................................5C-5
On-Vehicle Service.................................................5C-5
Bleeding of Clutch System...................................5C-5
Clutch Disc......................................................... 5C- 6
Master Cylinder.................................................5C-10Clutch Pedal...................................................... 5C-12
Clutch Oil Chamber........................................... 5C-14
Diagnosis............................................................ 5C-15
Clutch Slips....................................................... 5C-15
Poor Disengagement ......................................... 5C-15
Hard to Shift or Will not Shift............................... 5C-15
Clutch Chatters When Starting........................... 5C-15
Difficult Pedal Operation.................................... 5C-16
Clutch Noisy...................................................... 5C-16
Special Tools and Equipment............................ 5C-17
Special Tools Table............................................ 5C-17
SECTION 5C
CLUTCH
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 this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.
TABLE OF CONTENTS
Page 1358 of 2053
SSAMGYONG MY2002
5C-2 CLUTCH
Clutch Cover Bolt
Clutch Housing Bolt
Clutch Release Cylinder
Master Cylinder Nut
Clutch Tube Nut
Pedal Push Rod Nut
Pedal Mounting
T/M Case BoltBracket Bolt
Stopper Bolt24
54
30 - 40
8 - 18
15 - 18
16 - 22
8 - 18
21 - 25
74 Free
With Load
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Type
Clutch Pedal
Clutch Dise
Clutch Master Cylinder
Clutch Release Cylinder
Clutch FluidHydraulic
Suspended
158 mm
5 - 10 mm
Single Dry Diaphragm
9.85 - 10.2 mm
9.2 mm
19.8 mm
φ 15.87 mm
14.0 mm
φ 17.46 mm
SAE J1703 / DOT3Description
Type
Max. Pedal Stroke
Pedal Free Play
Type
Thickness of Disc
Stroke
Inner Diameter
Stroke
Inner Diameter
FASTENER TIGHTENING SPECIFICATIONS
17.7
39.8
22.1 - 29.5
8.9 - 13.2
11.0 - 13.2
11.8 - 16.2
8.9 - 13.2
15.4 - 18.4
54.5 N
z z z z
zm ApplicationLb-InLb-Ft
212.4
477.9
265.5 - 354.0
70.8 - 159.3
132.7 - 159.3
141.6 - 194.7
70.8 - 159.3
185.8 - 221.2
654.9
Page 1359 of 2053
CLUTCH 5C-3
SSANGYONG MY2002
1 Clutch Disc
2 Clutch Cover
3 Clutch Housing
4 Release Bearing
5 Release Fork Pivot
6 Release Cylinder
7 Release Fork Boot
COMPONENT LOCATOR
CLUTCH ASSEMBLY
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
KAA5C010
Notice: Apply the long-term grease (DBL 6811.00) to No.12,13 and 14.
Page 1360 of 2053
CLUTCH 5C-5
SSANGYONG MY2002
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.
KAA5C030
MAINTENANCE AND REPAIR