2003 SSANGYONG MUSSO Service Manual

5B-36 MANUAL TRANSMISSION
SHIFT COVER Disassembly Procedure
1. Using a hammer and a pin punch (3/16) remove the selectorarm roll pin.
2. Before removal, note the correct position of the interlock plate and selector arm and remove the shift shaft.
3. Check and clean all removed parts and replace if necessary. Assembly Procedure
1. If the shaft cup plug was removed, apply plug outer surface with sealer and install it into the cover.
2. Install the fork pads and selector plates onto the 1-2 and 3- 4 shift forks.
3. Assemble the sift cover parts as follows : Push the shift shaft into the cover until the front of the shaft
is at the inside of the cover.

MANUAL TRANSMISSION 5B-37
Install the 1-2 shift fork and its selector plate.
Push the shift shaft through the 1-2 shift fork.
Place the selector arm and interlock plate in the cover Note the position of the interlock plate and selector arm.
Push the shift shaft through the 3-4 shift fork.

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

MANUAL TRANSMISSION 5B-39
Selector 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 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.