2003 SSANGYONG MUSSO lock

5B-30 MANUAL TRANSMISSION
Assembly Procedure
1. When assemble the synchronizer, make sure that the hubsand sleeves are matched and the 3 keys are installed
properly. Also align blocking rings with keys during installation. Notice
Before assembly, coat all parts with lubricant. In case of the paper-lined blocking rings, soak them in Dexron II/III before
installation.
2. Assemble the following parts : 1st speed blocking ring.
Alignment pin and 1st speed gear bearing race.
1st speed gear and its bearing.
3. Install the rear bearing assembly to the main shaft.
4. Using a hydraulic press and installer, press the 5th driven gear onto the main shaft. While the main shaft is still on the press bed, install the 5th driven gear snap ring. If the snap
ring does not fit completely, continue pressing the 5th driven
gear.
5. Install the following parts : 2nd speed blocking ring assembly.
Thrust washer for the blocking ring inner cone.
Spiral retaining ring (Use special tools).
2nd speed gear spacer, bearing and gear.
2nd gear thrust washer and snap ring.
3rd speed gear spacer, bearing and gear.
3rd speed blocking ring.

MANUAL TRANSMISSION 5B-31
6. Using a hydraulic press and installer, install the 3-4synchronizer hub onto the main shaft. NoticeAlign the blocking ring with the synchronizer keys while installing the hub.

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.

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.

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.

Type Clutch Pedal Clutch Disc Clutch Master Cylinder Clutch Release Cylinder Clutch FluidDescription
Hydraulic
Suspended 158 mm
5 - 10 mm
Single Dry Diaphragm
9.85 - 10.2 mm 9.2 mm
19.8 mm
15.87 mm
14.0 mm
17.46 mm
SAE J1703 / DOT3
SECTION 5C
CLUTCH
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 General Specifications . . . . . . . . . . . . . . . . . . 5C-1
Fastener Tightening Specifications . . . . . . . . . 5C-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5C-3 Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5C-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Clutch Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4
Poor Disengagement . . . . . . . . . . . . . . . . . . . 5C-4
Hard to Shift or Will not Shift . . . . . . . . . . . . . . 5C-4
Clutch Chatters When Starting . . . . . . . . . . . . 5C-4
Difficult Pedal Operation . . . . . . . . . . . . . . . . . 5C-5
SPECIFICATIONS
GENERAL SPECIFICATIONS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
Application
Type Max. Pedal StrokePedal Free Play
TypeThickness of Disc Stroke Inner DiameterStrokeInner DiameterFree
With Load
Clutch Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5
Component Locator . . . . . . . . . . . . . . . . . . . 5C-6 Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . 5C-6
Pedal and Master Cylinder . . . . . . . . . . . . . . . 5C-7
Maintenance and Repair . . . . . . . . . . . . . . . 5C-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 5C-8
Bleeding of Clutch System . . . . . . . . . . . . . . . 5C-8
Clutch Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 5C-13
Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15
Clutch Oil Chamber . . . . . . . . . . . . . . . . . . . 5C-17

CLUTCH 5C-3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
602 589 00 40 00 Engine Lock 661 589 00 15 00
Centering Pin