2003 SSANGYONG MUSSO wheel

MANUAL TRANSMISSION 5B-5
Check
Clutch not releasing. Improper or low transmission oil. Shift or shift rail binding. Binding of sliding synchronizers or gears.
If reverse only, faulty backup switch. Worn or damaged flywheel pilot bushing. Check
Control lever assembly broken or damaged.
Damaged offset lever, shift fork, selector place or selector arm. DIAGNOSIS
WILL NOT SHIFT(CONTROL LEVER MOVES)
Action
Replace control lever and housing assembly.
Remove extension, adapter or case cover. Check or replace damaged parts.
HARD SHIFT OR CONTROL LEVER WILL NOT MOVE INTO GEAR
Action
Adjust or replace clutch. Add or replace with specified oil.
Remove extension, adapter or case cover. Check or replace damaged parts.
Remove extension, adapter or case cover. Check synchronizers and gears and replace damaged parts. Check or replace backup switch. Replace pilot bushing.
GEARS CRASH WHEN SHIFTING
Check
Engine idle speed too high. Damaged or faulty clutch.Pilot bearing between input shaft and output shaft binding.
Damaged synchronizer. Bell housing misaligned. Damaged gear(s).Worn or damaged flywheel pilot bushing. Action
Adjust idle speed to specified speed.Adjust or replace clutch.Replace or check roller bearings.Check or replace synchronizer parts. Align bell housing and bore. Check or replace gear(s).Replace pilot bushing.

5B-6 MANUAL TRANSMISSIONCheck
Loosened transmission or flywheel housing bolts,
improper alignment.Synchronizer damaged or excessively worn. Blocking ring damaged, worn index slots or friction surfaces worn or damaged.
Excessive countershaft end play. Worn or damaged fork due to loosened shaft, rail or shifting fork. TRANSMISSION JUMPS OUT
Action
Tighten bolts to specified value. Realign if necessary. Check or replace synchronizer parts.
Check or replace blocking ring.Check worn or damaged parts. Adjust shim thickness
using roller bearings if necessary.Check for wear or damaged. Replace worn or damaged parts.
Check
Fork or offset lever loose on shaft or rail.
Worn or damaged forks, offset lever, shaft or rail.
Worn or damaged synchronizer. Worn or damaged gears. TRANSMISSION LOCKED IN ONE GEARAction
Replace extension, adapter or case cover. Check or replace loose parts on shaft or rail. Replace roll pin(s).
Remove extension, adapter or case cover. Check forwear or damaged. Replace damaged parts.Check worn or damaged synchronizer parts and
replace if necessary.
Check worn or damaged gears and replace if neces-
sary.
Check
Improper or low transmission oil. Loose bolts or other attaching parts.Improper flywheel housing to engine crankshaftalignment.Noisy transmission bearing. Noisy gears. TRANSMISSION NOISEAction
Add or drain and replace with proper oil.
Tighten as specified.
Realign correctly. Check bearings, bearing rollers and parts for wear or damage.
Replace if necessary.Check for worn or damaged gears(including speedometer gear).
Replace if necessary.

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.

5C-4 CLUTCHChecks
Oily Facing Hard or Faulty Facing
Burnt Torsion Spring Faulty Pressure Plate Bent Clutch Diaphragm SpringHard or Bent FlywheelEngine Mounts Loose or Burnt Lever Action
Adjust Pedal Freeplay
Repair Release Cylinder Repair or Replace
Repair as Necessary Replace
Checks
Excessive Clutch Pedal Free play Faulty Clutch Release Cylinder Worn Disc, Excessive Run-out, Damaged LiningDirty or Burred Splines on Input Shaft or Clutch DiscDamaged Clutch Pressure Plate Checks
Vibration or Excessive Run-out of DiscRust or Wear of Disc Spline Oily Facing Damaged Diaphragm SpringExcessive Clutch Pedal Free play DIAGNOSIS
CLUTCH SLIPS
Checks
Excessive Wear of Facing Hard or Oily FacingDamaged Pressure Plate or FlywheelDamaged or Burnt Diaphragm SpringClutch Pedal Free play Insufficient Faulty Operation of Clutch Pedal Worn or Damaged Clutch Disc Action
Replace
Repair or Replace ReplaceReplaceAdjust
Repair or Replace Replace
POOR DISENGAGEMENT
Action
Replace
Repair or Replace Repair or Replace Replace
Adjust
HARD TO SHIFT OR WILL NOT SHIFT
CLUTCH CHATTERS WHEN STARTING
Action
Repair or Replace
Replace Replace Replace Replace
Repair or Replace
Tighten or Replace

5C-10 CLUTCH Removal & Installation Procedure
1. Remove the starter motor. Install the special tool to theflywheel 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. NoticeBe 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
Before installation, clean oil and grease on the flywheel surface.
Do not clean the clutch disc and release bearing insolvent.

TRANSFER CASE (PART TIME 4408) 5D1-3
Cannot Front Wheel Drive when Shifted 4H,4LDIAGNOSIS
Electric Shift Problems
Action
Overhaul and check, replace if necessary. Overhaul and check for wear and damage.
Replace if necessary.
Check sliding parts, replace if necessary.
Checks
Faulty or Damaged TCCU, Speed Sensor, Motor, Clutch or Internal Wirings Damaged or Worn Shift Cam, Hub, Fork and Rail Shift Binding Shift Fork, Hub Collar or Gear
Checks
Broken Drive Chain Action
Check sliding parts, replace if necessary.
Noise in 4WD Operation
Checks
Improper or low oil Loosened bolts or mounted partsNoisy T/C bearing Noisy gears Action
Drain and replace with specified oil. Retighten as specified.Disassemble bearings and parts and check for wear or
damage. Replace if necessary. Check for wear and damage including speedometer
gear, replace if necessary.
Noise in 4H or 4L
Checks
Worn or Damaged Sprockets or Drive Chain
Incorrect Tire Pressure Action
Disassemble and check for wear and damage, replace
if necessary. Adjust tire pressure.
Transfer Case Oil Leakage
Action
Replace the case. Clean case and parts and check for leakage.
Remove breather hose and clean, replace if necessary.Use specified oil and adjust oil level.Retighten Use specified sealant and retighten. Replace
Checks
Cracked Transfer CaseLeakage from Other PartsBreather CloggingImproper or too much OilLoosened Sealing Bolts Improperly Applied Sealant Worn or Damaged Oil Seal

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.