1998 SSANGYONG MUSSO torque

5B-24 MANUAL TRANSMISSION
7. Install the counter shaft rear bearing outer race, shim and
retainer.
Tightening Torque
39 - 52 Nm
lUsing a punch and hammer, bend the lock tabs on the
retainer.
8. Install the following parts :
lInstall the main shaft into case.
lInstall the main shaft rear bearing outer race into the
rear of the case.
lInstall the 4th speed blocking ring onto the front of the
main shaft.
lInstall the input shaft onto the front of the main shaft.
lInstall the input bearing retainer without shim onto the
front of the case.
lUsing a torque wrench, tighten the 4 bolts.
9. Install the 5th speed drive gear and blocking ring on the
counter shaft.
10. Install the 5th synchronizer and rail/fork.
11. Install the 5th synchronizer snap ring and oiling funnel.
12. Align the slots of the lever with the rollers of the reverse
fork and 5th shift rail. Apply sealer on the 5-R lever pivot
bolt and install it into the case.
Tightening Torque 28 Nm
13. Using a needle nose pliers, install the 5-R lever clip.

5C-10 CLUTCH
Removal & Installation Procedure
1. Remove the starter motor. Install the special tool to the
flywheel through the starter motor mounting holes.
Tightening Torque
47 Nm
Engine Lock 602 589 00 40 00
2. Unscren the release cylinder mounting bolts and remove
the release cylinder.
Installation Notice
3. Unscrew the clutch housing bolts and remove the clutch
housing, release fork and release bearing.
Installation Notice
4. Insert the centering pin into the clutch spline.
Loosen the clutch cover bolts 1/2 turn in crisscross sequence
until the spring tension is released.
Notice
Do not remove the bolts at a time, or clutchcover can be
damaged or deformed.
Centering Pin 661 589 00 15 00
Tightening Torque
30 - 40 Nm

CLUTCH 5C-11
5. Unscrew the bolts and remove the clutch cover, pressure
plate and clutch disc.
Notice
Be careful not to drop the pressure plate and clutch disc.
Installation Notice
Tightening Torque 21 - 27 Nm
6. Installation should follow the removal procedure in the
reverse order.
Notice
lBefore installation, clean oil and grease on the
flywheel surface.
lDo not clean the clutch disc and release bearing in
solvent.

5C-14 CLUTCH
Removal & Installation Procedure
1. Draw out the fluid.
2. Pull out the snap pin and clevis pin from the clutch pedal
connection.
3. Remove the clutch tube.
Installation Notice
Tightening Torque 15 - 18 Nm
Notice
Be careful not the fluid contact a painted surface.
4. Remove the master cylinder mounting nuts and pull off the
master cylinder.
Installation Notice
Tightening Torque 8 - 18 Nm
5. Check the clutch pedal operation.
6. Bleed the clutch system.

5D1-10 TRANSFER CASE (PART TIME 4408)
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
MAINTENANCE OF TRANSFER CASE
LUBRICANT
Oil Level Check
lClean the oil level plug and surrounding area.
lRemove the oil level plug and check whether oil is drip
out or not.
lTighten the oil level plug.
Oil Change
lClean the oil level plug and surrounding area
lPlace a suitable container under the transfer case.
lRemove the oil and tighten the drain plug.
lFill the oil through the oil level plug until oil begins to
drip out.
lTighten the oil level plug.
Cautions for oil level check and plugs tightening
lDo not use an impact wrench to remove or tighten the
oil level plug or drain plug since this will damage the
threads in the transfer case.
Tightening Torque 20 - 30 Nm

5D1-12 TRANSFER CASE (PART TIME 4408)
Removal & Installation Procedure
1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the drain plug and drain the oil.
Reinstall the drain plug.
* If planar damper is installed, unscrew 4 bolts and remove
the planar damper.
Installation Notice
Tightening Torque 19 - 30 Nm
4. Remove the breather hose.
5. Disconnect the speedometer cable connector and other
cable connectors and wiring harnesses.
6. Support the transfer case with jack and remove the front
and rear propeller shafts from the transfer case.
Installation Notice
Front
Rear81 - 89 Nm
70 - 80 NmTightening Torque

TRANSFER CASE (PART TIME 4408) 5D1-13
7. Remove the center mounting nuts and end sides mounting
bolts of the cross member and then remove the cross
member.
Installation Notice
Tightening Torque(1)
Tightening Torque(2)21 - 35 Nm
62 - 93 Nm
8. Remove the transfer case by removing the bolts attaching
the transfer case to the transmission.
Installation Notice
Notice
Apply long-term grease to the inner spline of the transfer
case input shaft.
9. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 38 - 51 Nm

5D1-28 TRANSFER CASE (PART TIME 4408)
6. Install the planet carrier assembly onto the input shaft
and install the thrust washer. Press the bearing over
input shaft.
7. After pressing the bearing, install the retaining ring.
8. Press the pin into the front adapter.
9. Slowly press the oil seal into the front adapter.
10. Install the front adapter assembly.
Notice
After installation, make sure that snap ring is correctly
installed into the groove.
11. Position the input shaft assembly over front cover and
engage into the bearing groove by expanding the ends of
snap ring.
12. Apply 1.6mm bead of sealant on the mounting face for
the transfer case and tighten the 6 bolts.
13. Install the breather.
75 Snap Ring
76 Oil Seal
77 Spiral Pin
78 Front Adapter
82 Sleeve Bearing
83 Needle Bearing
8 4 Input Shaft
Item
6 Bolts
BreatherTightening Torque
28 - 48 Nm
8 - 20 Nm