1998 SSANGYONG MUSSO manual transmission

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

5B-14 MANUAL TRANSMISSION
TRANSMISSION
Preceding Work : Removal of the shift control cable
1 Clutch Housing
2 Oil Filler Plug............................................ 25 Nm
3 Transmission Assembly
4 Back-up Switch
5 Washer
6 Bolt......................................................77-87 Nm
7 Oil Drain Plug............................................ 25 Nm
8 Bolt......................................................81-89 Nm
9 Washer
10 Front Propeller Shaft
11 Transfer Case Assembly12 Speedometer Cable
13 Rear Propeller Shaft
14 Washer
1 5 Bolt......................................................70-80 Nm
16 Cross Member
17 Washer
1 8 Bolt......................................................21-35 Nm
19 Washer
2 0 Bolt......................................................62-93 Nm
21 Breather Hose

MANUAL TRANSMISSION 5B-15
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 from the transmission housing and
drain the oil. Reinstall the drain plug.
Installation Notice
Tightening Torque
25 Nm
4. Disconnect the back-up switch connector.
5. Remove the breather hose.
6. Remove the speedometer connector and other wiring
harnesses and connectors.

5B-16 MANUAL TRANSMISSION
7. Remove the front and rear propeller shafts from the
transfercase.
Installation Notice
Tightening Torque81 - 89 Nm
70 - 90 NmFront
Rear
8. Support the transmission on an suitable jack.
Unscrew the center mounting nuts and each sides
mounting bolts and remove the cross member.
Installation Notice
9. Remove the transmission mounting bolts.
Installation Notice
Tightening Torque (1)
Tightening Torque (2)21 - 35 Nm
62 - 93 Nm
10. Move the transmission jack backward careful and
disengage the transmission input shaft from the engine.
Remove the transmission.
11. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 77 - 87 Nm

MANUAL TRANSMISSION 5B-17
UNIT REPAIR
MAJOR UNIT
Preceding Work : Removal of the transmission
Removal of the transfer case
Disassembly Procedure
1. Install the removed transmission into a fixture.
2. Remove the drain plug and drain the oil. Using a 13 mm
wrench, remove the clamp bolt and position the offset lever
in the 3-4 position of neutral.
Notice
Removal of the offset lever in a position other than 3-4 of
neutral will be difficult.
3. Using a pin punch and a hammer, remove the roll pin to
remove the shift lever from the offset lever.
4 . Using a 15 mm wrench, remove the 8 bolts from the extension
housing.
5. Separate the extension housing from the case and shift
cover.
Separate the offset lever from the shift.
Notice
Do not remove the offset lever while the extension housing
is still assembled to the case.
6. Remove the offset lever from the extension housing with
the detent ball and spring.
7. Remove the roll pin from either the offset lever or extension
housing.

5B-18 MANUAL TRANSMISSION
8. Remove the counter shaft thrust race and bearing.
9. Carefully remove the oiling funnel from the end of the
counter shaft.
10. Using a 10 mm wrench, remove the 10 bolts from the shift
cover.
Notice
For assembly, note the location of the two bolts.
11. Lift up the shift cover after sliding it toward the drain plug
about 3 cm. At this time remove sealer bond.
12. Using a needle nose pliers, remove the 5-R lever clip.

MANUAL TRANSMISSION 5B-19
13. Using a 21 mm wrench or a T-50 bit, remove the 5-R lever
pivot bolt.
Notice
Apply sealer bond to this bolt during assembly.
14. Using a 22 mm wrench, remove the back-up lamp switch
from the 5-R lever side.
Notice
Apply sealer to the threads.
15. Pull out the 5-R lever out of the transmission.
16. Using a snap ring pliers, remove the 5th synchronizer snap
ring from the end of the counter shaft.
17. Remove the 5th synchronizer assembly with its fork and
rail assembly from the counter shaft.

5B-20 MANUAL TRANSMISSION
18. Remove the slip yoke snap ring from the main shaft.
19. Remove the 5th speed drive gear snap ring from the main
shaft.
20. Make alignment marks on the case and input bearing
retainer and remove the 4 input shaft bearing retainer bolts,
using a 13 mm wrench.
Notice
Apply sealer on these bolts during assembly.
Remove the input bearing retainer with the bearing outer
race and shim.
21. Remove the input shaft from the case by rotating it until
the flat surface appears.
22. Remove the following parts from the input shaft.
l4th speed gear blocking ring.
lMain shaft thrust race and bearing.
lMain shaft pilot bearing rollers (15 rollers).
Notice
Be careful not to dissipate the pilot bearing rollers.