2003 SSANGYONG MUSSO oil

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-14 MANUAL TRANSMISSION TRANSMISSION Preceding Work : Removal of the shift control cable
1 Clutch Housing
2 Oil Filler Plug............................................ 25 Nm
3 Transmission Assembly
4 Back-up Switch
5 Washer
6 Bolt ...................................................... 77-87 Nm
7 Oil Drain Plug ............................................ 25 Nm
8 Bolt ...................................................... 81-89 Nm
9 Washer
10 Front Propeller Shaft 11 Transfer Case Assembly12 Speedometer Cable
13 Rear Propeller Shaft
14 Washer
15 Bolt ...................................................... 70-80 Nm
16 Cross Member
17 Washer
18 Bolt ...................................................... 21-35 Nm
19 Washer
20 Bolt ...................................................... 62-93 Nm
21 Breather Hose

MANUAL TRANSMISSION 5B-15
Removal & Installation Procedure
1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the drain plug from the transmission housing anddrain the oil. Reinstall the drain plug.Installation Notice
Tightening Torque 25 Nm
4. Disconnect the back-up switch connector.
5. Remove the breather hose.
6. Remove the speedometer connector and other wiring harnesses and connectors.

MANUAL TRANSMISSION 5B-17
UNIT REPAIR MAJOR UNIT Preceding Work : Removal of the transmissionRemoval of the transfer case
Disassembly Procedure
1. Install the removed transmission into a fixture.
2. Remove the drain plug and drain the oil. Using a 13 mm wrench, remove the clamp bolt and position the offset lever in the 3-4 position of neutral. NoticeRemoval of the offset lever in a position other than 3-4 of neutral will be difficult.
3. Using a pin punch and a hammer, remove the roll pin to remove the shift lever from the offset lever.
4 . Using a 15 mm wrench, remove the 8 bolts from the extension housing.
5. Separate the extension housing from the case and shift cover. Separate the offset lever from the shift.NoticeDo not remove the offset lever while the extension housing is still assembled to the case.
6. Remove the offset lever from the extension housing with the detent ball and spring.
7. Remove the roll pin from either the offset lever or extension housing.

5B-18 MANUAL TRANSMISSION
8. Remove the counter shaft thrust race and bearing.
9. Carefully remove the oiling funnel from the end of thecounter shaft.
10. Using a 10 mm wrench, remove the 10 bolts from the shift cover. Notice
For assembly, note the location of the two bolts.
11. Lift up the shift cover after sliding it toward the drain plug about 3 cm. At this time remove sealer bond.
12. Using a needle nose pliers, remove the 5-R lever clip.

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.

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

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