1998 SSANGYONG MUSSO transmission

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.

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.

5C-6 CLUTCH
COMPONENT LOCATOR
CLUTCH ASSEMBLY
1 Clutch Disc
2 Clutch Cover
3 Clutch Housing
4 Release Bearing
5 Release Fork Pivot
6 Release Cylinder
7 Release Fork Boot8 Bolt
9 Release Fork
1 0 Bolt
11 Spring Lock Washer
12 Transmission Input Spline
13 Release Bearing Contacting Surface
14 Contacting Point of Release Fork and Pivot
Notice
Apply the long-term grease (DBL 6811.00) to No.12,13 and 14.

CLUTCH 5C-9
CLUTCH DISC
Preceding Work : Removal of the transmission
1 Clutch Disc
2 Clutch Cover Assembly
3 Release Bearing
4 Clutch Housing
Tools
602 589 00 40 00 Engine Lock
661 589 00 15 00 Centering Pin5 Washer
6 Bolt........................................................... 23 Nm
7 Washer
8 Bolt........................................................... 44 Nm