1998 SSANGYONG MUSSO Workshop Repair Manual

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.

MANUAL TRANSMISSION 5B-7
TRANSMISSION LEAKAGE
Check
Leakage from transmission.
Vent or breather clogged.
Too much oil.
Loose bolts at sealing faces.
Improperly applied sealant.
Worn or damaged oil seal.Action
Clean all exposed surfaces, then check for leaks.
Clean or replace vent or breather.
Check oil level.
Tighten as specified.
Clean leaking surfaces.
Reapply sealant.
Replace oil seal.

5B-8 MANUAL TRANSMISSION
1 Shift Hop-out
2 Shift Gear Crash
3 Shift Block-out
4 Hard Shift
5 Noise in Reverse Gear
6 Noise in 5th Gear
7 Noise in 4th Gear
8 Noise in 3rd Gear
9 Noise in 2nd Gear
10 Noise in 1st Gear
11 Noise in All Speeds
12 Leak at Transmission Rear Part
13 Leak at Transmission Center Part
14 Leak at Transmission Front
DIAGNOSIS TABLE
Condition
Possible Faulty Part
Transmission Case
Extension Housing
Shift Cover / Shift Shift
Shift Control Lever
Input Bearing Retainer
Input Gear Set
3rd Speed Gear Set
2nd Speed Gear Set
Reverse Speed Gear Set
1st Speed Gear Set
5th Speed Gear Set
Clutch Housing and Release Derive
Crankshaft Pilot Bushing and Release Bearing
Input Bearing
Main Shaft Input Bearing
Main Shaft Thrust Bearing
3rd Speed Gear Bearing
2nd Speed Gear Bearing
1st Speed Gear Bearing
Reverse Idler Gear Bushing
Counter Shaft Front Bearing
Counter Shaft Rear Bearing
Counter Shaft Thrust Bearing
5th Speed Drive Gear Bearing
Slip Yoke Bushing
Slip Yoke Seal
Speedometer Drive / Driven Gears
Speedometer Driven Gear Housing
Input Shaft Seal
1 - 2 Synchronizer Assembly
3 - 4 Synchronizer Assembly
5th Synchronizer Assembly
Ring Oil Seal
T/C Front Facel
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MANUAL TRANSMISSION 5B-9
COMPONENT LOCATOR

5B-10 MANUAL TRANSMISSION
1 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
1 2 Bolt
13 Extension and Plate Assembly
14 O-Ring & Steel Ring
15 Oiling Funnel
1 6 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
2 7 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 Assembly38 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
4 9 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 Sleeve73 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
9 4 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

MANUAL TRANSMISSION 5B-11
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
SHIFT CONTROL CABLE
1 Shift Lever Assembly
2 Bolt......................................................20-30 Nm
3 Select Cable
4 Shift Cable
5 Snap Pin
6 Snap Pin
7 Transmission
8 Shift Cable9 Select Cable
1 0 Clip
11 Clip
12 Snap Pin
13 Snap Pin
14 Protector
15 Washer

5B-12 MANUAL TRANSMISSION
Removal & Installation Procedure
1. Position the shift lever in neutral and remove the knob.
2. Remove the screw from the console box side and remove
the shift lever cover.
3. Disconnect the cables by removing the snap pins from the
control cable connections to the select lever and shift lever.
4. Remove the shift lever an cable mounting snap pin and
washer of the select lever.

MANUAL TRANSMISSION 5B-13
5. Pull out the clip from the bracket and remove the shift cable
and select cable.
6. Installation is reverse order of the removal.
Inspection Procedure
1. The shift lever should be positioned in neutral.
2. Apply liquid gasket on the cable contact surface.
3. Keep 130 mm between the center of the cable end-eye
and floor.
Notice
If necessary, adjust the adjust nut.
Standard 130 mm