1997 SSANGYONG KORANDO Pedal

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

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 zz 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

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

CLUTCH 5C-11
SSANGYONG MY2002
Removal & Installation Procedure
1. Draw out the fluid.
2. Pull out the snap pin and clevis pin from the clutch
pedal connection.
3. Remove the clutch tube.
Installation Notice
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
5. Check the clutch pedal operation.
6. Bleed the clutch system.
KAA5C140
Tightening Torque15 - 18 Nm
(11 - 13 lb-ft)
Tightening Torque8 - 18 Nm
(6 - 13 lb-ft)

SSAMGYONG MY2002
5C-12 CLUTCH
1 Snap Pin .................................................Replace
2 Clevis Pin......................................Apply Grease
3 Master Cylinder Push Rod
4 Gasket
5 Nut ............................ 16 - 32 Nm (12 - 24 lb-ft)
6 Spring Washer
7 Bolt................................ 8 - 18 Nm (6 - 13 lb-ft)
8 Fulcrum Pin
CLUTCH PEDAL
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 Clutch Interlock Switch
KAA5C150
Notice: Assembly should follow the disassembly procedure in the reverse order.
Grease specification: Long - term grease (T/Mn DBL6611.00)

CLUTCH 5C-13
SSANGYONG MY2002
Inspection Procedure
1. Pedal Stroke (A).
Installation Notice
Notice: To adjust the pedal stroke, loosen the lock
nut (H) of the interlock switch (G) and turn the two
lock auto until the stroke is correct.
2. Pedal Height (B).
Installation Notice
Notice: To adjust the pedal height, loosen the lock
nut (C) of the stopper bolt (D) and turn the stopper
bolt until the height is correct.
3. Pedal Free Play (E).
Installation Notice
Notice: To adjust the pedal free play, loosen the
lock nut (F) of the master cylinder and turn the
push rod until the free play is correct.
4. Check the fulcrum pin and the bushing for wear,
the pedal for bending and the spring for damage.
KAA5C160
Max. Stroke 158 mm
Height
(From the Floor Carpet)147 - 187 mm
Free Play 5 - 10 mm

CLUTCH 5C-15
SSANGYONG MY2002
Replace
Repair or Replace
Replace
Replace
Adjust
Repair or Replace
Replace Excessive Wear of Facing
Hard or Oily Facing
Damaged Pressure Plate or Flywheel
Damaged or Burnt Diaphragm Spring
Clutch Pedal Free play Insufficient
Faulty Operation of Clutch Pedal
Worn or Damaged Clutch DiscAction Checks
DIAGNOSIS
CLUTCH SLIPS
Replace
Repair or Replace
Repair or Replace
Replace
Adjust Vibration or Excessive Run-out of Disc
Rust or Wear of Disc Spline
Oily Facing
Damaged Diaphragm Spring
Excessive Clutch Pedal Free playAction Checks
POOR DISENGAGEMENT
Adjust Pedal Freeplay
Repair Release Cylinder
Repair or Replace
Repair as Necessary
Replace Excessive Clutch Pedal Free play
Faulty Clutch Release Cylinder
Worn Disc, Excessive Run-out, Damaged Lining
Dirty or Burred Splines on Input Shaft or Clutch Disc
Damaged Clutch Pressure PlateAction Checks
HARD TO SHIFT OR WILL NOT SHIFT
Repair or Replace
Replace
Replace
Replace
Replace
Repair or Replace
Tighten or Replace Oily Facing
Hard or Faulty Facing
Burnt Torsion Spring
Faulty Pressure Plate
Bent Clutch Diaphragm Spring
Hard or Bent Flywheel
Engine Mounts Loose or Burnt LeverAction Checks
CLUTCH CHATTERS WHEN STARTING

SSAMGYONG MY2002
5C-16 CLUTCH
Lubricate or Replace
Lubricate or Replace
Repair Poor Lubrication on Clutch Cable
Poor Lubrication on Pedal Shaft
Poor Lubrication on Clutch PedalAction Checks
DIFFICULT PEDAL OPERATION
Insufficient Clutch Pedal Free play
Excessive Wear of Facing
Worn or Damaged Release Bearing
Poor Lubrication Contact Surface of Bearing
Faulty Installation of Clutch Assembly or Bearing
Damaged Pilot Bushing Not Using the Clutch
After Disengagement
When Disengaging
Clutch Pedal is Partially Depressed
and Vehicle Speed is ReducedAction Checks
CLUTCH NOISY
Adjust
Replace
Replace
Replace
Repair
Replace