2003 SSANGYONG MUSSO lock

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-8 MANUAL TRANSMISSION1 Shift Hop-out 2 Shift Gear Crash 3 Shift Block-out 4 Hard Shift 5 Noise in Reverse Gear6 Noise in 5th Gear 7 Noise in 4th Gear 8 Noise in 3rd Gear 9 Noise in 2nd Gear 10 Noise in 1st Gear
11 Noise in All Speeds 12 Leak at Transmission Rear Part 13 Leak at Transmission Center Part 14 Leak at Transmission Front
DIAGNOSIS TABLE
Condition
Possible Faulty Part
Transmission Case Extension HousingShift Cover / Shift ShiftShift Control LeverInput Bearing RetainerInput Gear Set3rd Speed Gear Set2nd Speed Gear SetReverse Speed Gear Set1st Speed Gear Set5th Speed Gear SetClutch Housing and Release DeriveCrankshaft Pilot Bushing and Release BearingInput BearingMain Shaft Input BearingMain Shaft Thrust Bearing3rd Speed Gear Bearing2nd Speed Gear Bearing1st Speed Gear BearingReverse Idler Gear BushingCounter Shaft Front BearingCounter Shaft Rear BearingCounter Shaft Thrust Bearing5th Speed Drive Gear Bearing
Slip Yoke Bushing
Slip Yoke SealSpeedometer Drive / Driven GearsSpeedometer Driven Gear HousingInput Shaft Seal1 - 2 Synchronizer Assembly3 - 4 Synchronizer Assembly5th Synchronizer AssemblyRing Oil SealT/C Front Face

5B-10 MANUAL TRANSMISSION1 Filler/Drain Plug
2 Shift Mechanism Cover
3 Shift Shaft Lever
4 Outer Select Lever
5 Inner Select Lever
6 Offset Control Lever
7 Bias Spring
8 Bolt
9 Pin
10 Washer
11 Bolt
12 Bolt
13 Extension and Plate Assembly
14 O-Ring & Steel Ring
15 Oiling Funnel
16 Bolt
17 Alignment Bolt
18 Pin
19 Shift Shaft
20 3/4 Shift Fork
21 1/2 Shift Fork
22 Insert
23 Selector Arm Assembly
24 Interlock Plate Assembly
25 Selector Plate
26 O-ring
27 Plug
28 Case Cover
29 Retaining Ring
30 Pivot Pin
31 Back-up Switch
32 5/Reverse Shift Lever
33 Snap Ring
34 5th Synchronizer Retainer
35 5th Synchronizer Assembly
36 Synchronizer Spring
37 Synchronizer Assembly 38 Insert
39 Synchronizer Hub
40 Roll Pin
41 5th Shift Fork
42 Insert
43 Shift Rail Assembly
44 Blocking Ring
45 5th Speed Drive Gear
46 Snap Ring
47 Speed Gear
48 Speed Gear Clip
49 Bolt
50 Input Bearing Retainer
51 Oil Seal
5 2 Shim
53 Bearing Cup
54 Bearing Cone
55 Input Shaft
56 Roller Bearing
57 Spacer
58 Thrust Bearing
59 Thrust Bearing Race
60 5th Speed Driven Gear
61 Bearing Cup
62 Bearing Cone
63 1st Speed Gear
64 Bearing Sleeve Assembly
65 A. Bearing
65 B. Bearing
65 C. Spacer
66 Sleeve
67 Blocking Ring Assembly
68 3/4 synchronizer Assembly
69 Synchronizer Spring
70 Synchronizer Sleeve
71 Insert
72 Synchronizer Sleeve 73 3rd Speed Gear
74 Needle Bearing
75 Spacer
76 Snap Ring
77 Thrust Washer
78 2nd Speed Gear
79 2nd Speed Gear Bearing
80 Spacer
81 Output Shaft Assembly
82 Retaining Ring
83 Thrust Washer
84 Inner Cone
85 Outer Cone Race
86 1/2 Blocking Ring
87 Spring Gear
88 Reverse Sliding Gear
89 Insert Gear
90 Pin
91 Shaft and Hub Assembly
92 Spring
93 Pin Fork and Reverse Roller
Assembly
94 Bolt
95 Rear Bearing Retainer
9 6 Shim
97 Roll Pin
98 Reverse Idler Shaft
99 Reverse Idler Gear Assembly
100 O-ring
101 Bearing Cup
102 Bearing Cup Assembly
103 O-ring
104 Bearing Cup
105 Bearing Cone
106 Counter Shaft Gear
107 Transmission Case Assembly

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 mainshaft.
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. 4th speed gear blocking ring.
Main shaft thrust race and bearing.
Main shaft pilot bearing rollers (15 rollers).
Notice Be careful not to dissipate the pilot bearing rollers.

MANUAL TRANSMISSION 5B-21
23. Remove the main shaft in 2 steps.To remove the rear bearing outer race, push the main
shaft rearward.
Tilt and lift the main shaft from the case.
24. Remove the reverse fork and spring from the case.
25. Remove the counter shaft as follows: Using a punch and hammer, pry up the lock tabs.
Using a 13 mm wrench or T-40 bit, remove the 4 bolts.
Remove the retainer and shim from the case.
Push the counter shaft rearward to remove the rear
bearing outer race.

5B-24 MANUAL TRANSMISSION
7. Install the counter shaft rear bearing outer race, shim andretainer.
Tightening Torque 39 - 52 Nm
Using a punch and hammer, bend the lock tabs on the
retainer.
8. Install the following parts : Install the main shaft into case.
Install the main shaft rear bearing outer race into the
rear of the case.
Install the 4th speed blocking ring onto the front of the
main shaft.
Install the input shaft onto the front of the main shaft.
Install the input bearing retainer without shim onto the
front of the case.
Using 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.

5B-28 MANUAL TRANSMISSION
7. Using a screwdriver, remove the spiral retaining ring.
8. Remove the thrust washer and three-piece 2nd speedblocking ring assembly.
9. For correct reassembly, place an alignment mark on the 1-2 synchronizer hub and sleeve.
10. Remove the 1-2 synchronizer sleeve from the hub with following parts :
The anti-rattle ball and spring.
The three keys.
One of the 3 springs.
11. Using a hydraulic press and puller plate, remove the 5th speed driven gear from the main shaft.

MANUAL TRANSMISSION 5B-29
12. Remove the main shaft rear bearing assembly from theshaft.
13. Remove the 1st speed gear and bearing.
14. Remove the inner race.
15. Remove the tree-piece 1st speed blocking ring assembly and remaining synchronizer spring.
16. Check and clean all removed parts and replace if necessary.