1998 SSANGYONG MUSSO engine

AUTOMATIC TRANSMISSION 5A-81
Throttle Clearing
The leant throttle clearing routine uses the mode switch and gear lever. Carry out the following steps to complete the
automated throttle clearing procedure:
1. Switch ignition ‘ON’ with handbrake applied and engine ‘OFF’.
2. Select ‘M1’ and ‘WINTER’ mode.
3. Move the T-bar to ‘M2’ and then select ‘NORMAL’ or ‘POWER’ mode.
4. Move the T-bar to ‘M3’ and then select ‘WINTER’ mode.
Vehicle Coding
The vehicle coding is integrated as part of the diagnostic software. The coding applies to the following vehicle
models:
1. 4WD Gasoline E32.
2. 4WD Gasoline 523
3. 4WD Gasoline 520.
4. 4WD Diesel D29NA.
5. 4WD Diesel D29LA.
6. 4WD Diesel D23LA.
7. RWD E20.
8. RWD E23.

AUTOMATIC TRANSMISSION 5A-83
Tightening Torque 70 - 80 Nm
11. Remove the two pipes for oil cooler.
Installation Notice
Tightening Torque24.5 - 34.3 Nm
12. Remove the service hall cover on torque converter.
13. Put the alignment mark for installation, and unscrew the
six mounting bolts for torque converter from drive plate
through the service hole (arrow) by rotating the engine
and remove the torque converter.
Installation Notice
Tightening Torque 42 Nm
7. Remove the rear propeller shaft.
Installation Notice
8. Unscrew the five bolts and remove the transfer case.
9. Disconnect the 10-Pins Plug connector from transmission.
10. Separate the locking clip on shift lever and remove the
shift rod.
Notice
Removal and installation performed when the shift
procedure should be lever is in “D” range.
Screw the six bolts mounting the torque converter through
the service hole by using a mirror and rotating the engine.

MANUAL TRANSMISSION 5B-5
Check
Clutch not releasing.
Improper or low transmission oil.
Shift or shift rail binding.
Binding of sliding synchronizers or gears.
If reverse only, faulty backup switch.
Worn or damaged flywheel pilot bushing.Check
Control lever assembly broken or damaged.
Damaged offset lever, shift fork, selector place or
selector arm.
DIAGNOSIS
WILL NOT SHIFT(CONTROL LEVER MOVES)
Action
Replace control lever and housing assembly.
Remove extension, adapter or case cover.
Check or replace damaged parts.
HARD SHIFT OR CONTROL LEVER WILL NOT MOVE INTO GEAR
Action
Adjust or replace clutch.
Add or replace with specified oil.
Remove extension, adapter or case cover.
Check or replace damaged parts.
Remove extension, adapter or case cover.
Check synchronizers and gears and replace
damaged parts.
Check or replace backup switch.
Replace pilot bushing.
GEARS CRASH WHEN SHIFTING
Check
Engine idle speed too high.
Damaged or faulty clutch.
Pilot bearing between input shaft and output shaft binding.
Damaged synchronizer.
Bell housing misaligned.
Damaged gear(s).
Worn or damaged flywheel pilot bushing.Action
Adjust idle speed to specified speed.
Adjust or replace clutch.
Replace or check roller bearings.
Check or replace synchronizer parts.
Align bell housing and bore.
Check or replace gear(s).
Replace pilot bushing.

5B-6 MANUAL TRANSMISSION
Check
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 GEAR
Action
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 for
wear 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 crankshaft
alignment.
Noisy transmission bearing.
Noisy gears.
TRANSMISSION NOISE
Action
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-16 MANUAL TRANSMISSION
7. Remove the front and rear propeller shafts from the
transfercase.
Installation Notice
Tightening Torque81 - 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 Nm
62 - 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

5B-46 MANUAL TRANSMISSION
lCheck the housing face alignment.
- Place the dial indicator on the housing face.
- By rotating the crankshaft one revolution, record the
dial indicator reading.
Notice
If the reading is greater than 0.010 inch, insert the shim
between the engine and clutch housing and adjust the
alignment.
5. Check the following parts :
lPressure plate spring assembly
lDisc
lFlywheel
lInput shaft pilot bearing
Notice
Replace the excessively worn parts.
6. Lubricate the clutch release bearing bore, fork pivot head
during assembly.

CLUTCH 5C-3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
602 589 00 40 00
Engine Lock661 589 00 15 00
Centering Pin

5C-4 CLUTCH
Checks
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
Adjust Pedal Freeplay
Repair Release Cylinder
Repair or Replace
Repair as Necessary
Replace Checks
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 PlateChecks
Vibration or Excessive Run-out of Disc
Rust or Wear of Disc Spline
Oily Facing
Damaged Diaphragm Spring
Excessive Clutch Pedal Free play
DIAGNOSIS
CLUTCH SLIPS
Checks
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
Replace
Repair or Replace
Replace
Replace
Adjust
Repair or Replace
Replace
POOR DISENGAGEMENT
Action
Replace
Repair or Replace
Repair or Replace
Replace
Adjust
HARD TO SHIFT OR WILL NOT SHIFT
CLUTCH CHATTERS WHEN STARTING
Action
Repair or Replace
Replace
Replace
Replace
Replace
Repair or Replace
Tighten or Replace