2003 SSANGYONG MUSSO manual transmission

5B-40 MANUAL TRANSMISSION
INSPECTION OF COMPONENTS Inspection Procedure
1. Clean all parts with solvent and dry them with compressedair. Check the following parts for cracks and damaged sealing surfaces.
Case
Extension housing
Shift Cover
Input bearing retainer
Counter 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 ; Input shaft
Main shaft and its gears
Counter shaft and 5th drive gear
4. Check the reverse idler shaft and its gears. NoticeReplace 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 : Wear of the shift shaft.
Wear of the detent/guide plate and offset lever.
Check 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.
Check 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: Crankshaft pilot bushing for the front of the input shaft.
Clutch release bearing.
Input shaft bearing.
Main shaft pilot bearing rollers.
Main shaft thrust Bearing and its surfaces.
Speed gear roller bearing on the main shaft.
Main shaft rear bearing.
Counter 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 : The 1-2 synchronizer.
The 5th blocking ring.
10. Check the fit between the hub and sleeve of each synchronizer
Excessively tight or loose hub-to-sleeve fit.
Wear of the cone clutch surfaces of brass blocking rings and gears.
11. Measure the clearance between the blocking ring and the speed gear
New 1-2 blocking ring : 0.87-1.4mm
New 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 orthe 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 removethe 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 : Place the magnetic base on the pressure plate spring.
Check 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
Check the housing face alignment.
- Place the dial indicator on the housing face.
- By rotating the crankshaft one revolution, record the
dial indicator reading.
NoticeIf the reading is greater than 0.010 inch, insert the shim between the engine and clutch housing and adjust thealignment.
5. Check the following parts : Pressure plate spring assembly
Disc
Flywheel
Input shaft pilot bearing
Notice
Replace the excessively worn parts.
6. Lubricate the clutch release bearing bore, fork pivot head during assembly.

5D1-36 TRANSFER CASE (PART TIME 4408)
TRANSFER CASE CONTROL UNIT (TCCU) System Description TCCU is located under the front left handed seat and permits the vehicle to shift from two-wheel drive to four-wheel drive
(and back shift) according to driver ’s switch operation during
driving (For the shifting between 4WD HIGH and 4WD LOW, stop the vehicle).
1. Shifting from 2H to 4H
Position the transfer case switch from '2H' to '4H'.
Shifting is possible during driving.
'4WD Hl' indicator light will turn on.
2. Shifting from 4H to 2H Position the transfer case switch from '4H' to '2H'.
Shifting is possible during driving.
'4WD Hl' indicator light will turn off.
3. Shifting between 4H and 4L Shifting is possible when the vehicle is almost stopped
(below approx. 2 km/h), so it would be better stop the vehicle.
In case of manual transmission equipped vehicle, apply
clutch pedal.
In case of auto transmission equipped vehicle, put the
lever position into 'N'.
Position the transfer case switch '4H' to '4L' or '4L' to
'4H'.
According to the shifted position, indicator light will turn
on.
Notice
If there are malfunctions during shifting,'4H' or '4L' indicator light will blink.