1998 SSANGYONG MUSSO Workshop Repair Manual

5B-38 MANUAL TRANSMISSION
lInstall the 3-4 shift fork and its selector plate.
lPush the shift shaft through the 3-4 shift fork.
lInstall the roll pin that fixes the selector arm to the shift
shaft.
4 . Check the shift cover parts for proper assembly as follows :
lInsert a pin punch (3/16) into the offset lever hole of
the shift shaft.
lPlace the shift cover to the flat ground and rotate the
shift shaft so that the punch is vertical.

MANUAL TRANSMISSION 5B-39
lSelector arm should be aligned with the 3/4 shift fork
selector plate.
5. Lubricate and install the O-ring on the rear of the shift cover.

5B-40 MANUAL TRANSMISSION
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.
lCase
lExtension housing
lShift Cover
lInput bearing retainer
lCounter shaft rear bearing retainer
2. Check the parts which support bearings and shafts for
excessive wear and replace them if necessary.
3. Check the bearing surfaces of the following parts ;
lInput shaft
lMain shaft and its gears
lCounter 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.

MANUAL TRANSMISSION 5B-41
5. Check the shift mechanism parts as follows :
lWear of the shift shaft.
lWear of the detent/guide plate and offset lever.
lCheck 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.
lCheck 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.

5B-42 MANUAL TRANSMISSION
6. Check the following Bearing for excessive war:
lCrankshaft pilot bushing for the front of the inputshaft.
lClutch release bearing.
lInput shaft bearing.
lMain shaft pilot bearing rollers.
lMain shaft thrust Bearing and its surfaces.
lSpeed gear roller bearing on the main shaft.
lMain shaft rear bearing.
lCounter shaft front and rear bearings.
7. Check the gear tooth surfaces of all gear sets.
8. Check the reverse gear set surfaces. Check the surfaces
of gear teeth for excessive wear, pitting, scoring and spalling
and replace if necessary.

MANUAL TRANSMISSION 5B-43
9. Take apart the three synchronizer assemblies and check :
lThe 1-2 synchronizer.
lThe 5th blocking ring.
10. Check the fit between the hub and sleeve of each
synchronizer
lExcessively tight or loose hub-to-sleeve fit.
lWear of the cone clutch surfaces of brass blocking
rings and gears.
11. Measure the clearance between the blocking ring and the
speed gear
lNew 1-2 blocking ring : 0.87-1.4mm
lNew 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.

5B-44 MANUAL TRANSMISSION
12. Check for gear clash on the synchronizer sleeve teeth or
the clutch teeth on the speed gear.
13. Check the synchronizer sleeve and gear clutch tooth for
hop-out.

MANUAL TRANSMISSION 5B-45
PRE-INSTALLATION CHECKS
Checking Procedure
1. Separate the clutch release fork from the pivot and remove
the pivot from the clutch housing.
2. Check the pivot. Fork and release bearing.
3. Check the pressure plate spring.
Notice
Inspect each parts and replace the excessively worn parts.
4. Check the clutch housing alignment as follows :
lPlace the magnetic base on the pressure plate spring.
lCheck the housing bore alignment.
- Place the dial indicator on the bore.
- By rotating the crankshaft one revolution, record the
dial indicator reading.