SsangYong Musso. Service manual - part 489

MANUAL TRANSMISSION  5B-3

EXTERNAL VIEW

GEAR TRAIN

5B-4  MANUAL TRANSMISSION

POWER FLOW

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 TRANSMISSION

Check

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 GEAR

Action

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 for

wear 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 crankshaft

alignment.

Noisy transmission bearing.

Noisy gears.

TRANSMISSION NOISE

Action

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.