1998 SSANGYONG MUSSO Workshop Repair Manual

5B-30 MANUAL TRANSMISSION
Assembly Procedure
1. When assemble the synchronizer, make sure that the hubs
and sleeves are matched and the 3 keys are installed
properly. Also align blocking rings with keys during
installation.
Notice
Before assembly, coat all parts with lubricant. In case of the
paper-lined blocking rings, soak them in DexronII/III before
installation.
2. Assemble the following parts :
l1st speed blocking ring.
lAlignment pin and 1st speed gear bearing race.
l1st speed gear and its bearing.
3. Install the rear bearing assembly to the main shaft.
4. Using a hydraulic press and installer, press the 5th driven
gear onto the main shaft. While the main shaft is still on the
press bed, install the 5th driven gear snap ring. If the snap
ring does not fit completely, continue pressing the 5th driven
gear.
5. Install the following parts :
l2nd speed blocking ring assembly.
lThrust washer for the blocking ring inner cone.
lSpiral retaining ring (Use special tools).
l2nd speed gear spacer, bearing and gear.
l2nd gear thrust washer and snap ring.
l3rd speed gear spacer, bearing and gear.
l3rd speed blocking ring.

MANUAL TRANSMISSION 5B-31
6. Using a hydraulic press and installer, install the 3-4
synchronizer hub onto the main shaft.
Notice
Align the blocking ring with the synchronizer keys while
installing the hub.

5B-32 MANUAL TRANSMISSION
INPUT SHAFT
Disassembly Procedure
1. Remove the following parts from the input shaft :
lMain shaft thrust race and bearing.
lMain shaft pilot bearing rollers (15 rollers).
2. Using a hydraulic press and puller plate, remove the input
shaft bearing assembly from the shaft.
3. Remove the input bearing.
4. Remove the input shaft seal.
5. Check and clean all removed parts and replace if necessary.

MANUAL TRANSMISSION 5B-33
Assembly Procedure
1. Using a hydraulic press and installer, press the input shaft
bearing onto the input shaft.
2. Apply grease to the thrust bearing inner roller (15 rollers)
and install the main shaft thrust bearing and its race in the
rear of the input shaft.
3. Using a rubber hammer and installer, install the input bearing
retainer and input shaft seal after applying grease.
4. Install the bearing outer race to the retainer without end
play adjusting shim.

5B-34 MANUAL TRANSMISSION
COUNTER SHAFT
Disassembly Procedure
1. Using a hydraulic press and special tool, remove the front
bearing assembly from the counter shaft.
2. Check and clean all removed parts and replace if necessary.
Assembly Procedure
1. Using a hydraulic press and installer, press the front bearing
assembly onto the counter shaft.
2. Install is as follows :
lInstall a new O-ring on the counter shaft outer race and
lubricate it.
lUsing a installer, lightly tap the race into its bore until the
O-ring is compressed.
lInstall the race to be fully seated on the inside of the
case.

MANUAL TRANSMISSION 5B-35
EXTENSION HOUSING
Disassembly Procedure
1. Remove the vent from the extension housing.
2. Remove the O-ring and steel ring from the rear of the
extension housing.
3. Check and clean all removed parts and replace if necessary.
Assembly Procedure
1. Install the O-ring and steel ring to the rear of the extension
housing.
2. Install the vent to the extension housing.

5B-36 MANUAL TRANSMISSION
SHIFT COVER
Disassembly Procedure
1. Using a hammer and a pin punch (3/16) remove the selector
arm roll pin.
2. Before removal, note the correct position of the interlock
plate and selector arm and remove the shift shaft.
3. Check and clean all removed parts and replace if necessary.
Assembly Procedure
1. If the shaft cup plug was removed, apply plug outer surface
with sealer and install it into the cover.
2. Install the fork pads and selector plates onto the 1-2 and 3-
4 shift forks.
3. Assemble the sift cover parts as follows :
Push the shift shaft into the cover until the front of the shaft
is at the inside of the cover.

MANUAL TRANSMISSION 5B-37
lInstall the 1-2 shift fork and its selector plate.
lPush the shift shaft through the 1-2 shift fork.
lPlace the selector arm and interlock plate in the cover
Note the position of the interlock plate and selector arm.
lPush the shift shaft through the 3-4 shift fork.