2003 SSANGYONG MUSSO filler

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

5D2-40 TRANSFER CASE (TOD)
REPLACEMENT OF OIL Oil Specification Specified Oil Level
SpecificationStandard
Capacity Service A.T.F S-3, S-4 or Dexron II, III
1.4 Litre
Inspection every 15,000km, Replacement every 50,000km =
Oil Replacement
1. Lift on vehicle then make sure on safety.
2. Prepare a vessel to drain transfer case oil.
3. Release filler plug.
4. Drain oil completely.
5. Wash drain plug and than tighten. Installation Notice
Tightening Torque 19 - 30 Nm
6. Replenish standardized oil by specified level through filler plug hole.
7. Tighten filler plug after washing.
Installation Notice
8. Check oil leakage.
Tightening Torque 19 - 30 Nm
. .

TRANSFER CASE (TOD) 5D2-53
40. Install the rear case flange on the output shaft. Install therubber seal, output shaft yoke washer and nut. Tighten the nut.
Tightening Torque 137 - 196 Nm
41. Install the drainplug and tighten.
42. Fill the transfer case with 1.4 liters of Automatic Transmission Fluid or equivalent. NoticeFluid level should be just below the filler plug hole.
Tightening Torque 19 - 30 Nm
Tightening Torque 19 - 30 Nm
43. Install the fill pulg and tighten.
44. Install the transfer case as outlined in removal and
Installation, transfer case in the section. NoticeMake sure proper drain and fill plugs are installed if case is replaced.

MUSSO-SPORTS 1A-15
SUPPLEMENT
KAA5A020
KAA5A020
KAA5A020Removal and Installation of Luggage Deck Preceding work: Removal of tail lamp assembly
1. After removing the tail lamp assembly, release upper
two screw and one lower. Screw of the side bumper cover.
KAA5A020 2. Carefully remove the cover of bumper side.
Note: Due to the opposite fixing section of the cover
screw of bumper side is the locking fastener, so it is fragile part careful remove this one.
3. After releasing four fixing bolt of rear bumper, and then remove the bumper.
4. Remove the wiring of tail lamp and the operation cable of fuel filler.