SsangYong Korando II (1996-2006 year). Manual — part 342
CLUTCH 5C-11
SSANGYONG MY2002
Removal & Installation Procedure
1. Draw out the fluid.
2. Pull out the snap pin and clevis pin from the clutch
pedal connection.
3. Remove the clutch tube.
Installation Notice
Notice: Be careful not the fluid contact a painted
surface.
4. Remove the master cylinder mounting nuts and
pull off the master cylinder.
Installation Notice
5. Check the clutch pedal operation.
6. Bleed the clutch system.
KAA5C140
Tightening Torque
15 - 18 N•m
(11 - 13 lb-ft)
Tightening Torque
8 - 18 N•m
(6 - 13 lb-ft)
SSAMGYONG MY2002
5C-12 CLUTCH
1 Snap Pin . . . . . . . . . . . . . Replace
2 Clevis Pin . . . . . . . . . .. Apply Grease
3 Master Cylinder Push Rod
4 Gasket
5 Nut . . . . . . . 16 - 32 N•m (12 - 24 lb-ft)
6 Spring Washer
7 Bolt . . . . . . . . 8 - 18 N•m (6 - 13 lb-ft)
8 Fulcrum Pin
CLUTCH PEDAL
9 Turn Over Spring . . . . . . .. Apply Grease
10 Bushing . . . . . . . Replace, Apply Grease
11 Full Stroke Stopper Contact Pad
12 Clutch Pedal
13 Pedal Pad
14 Pedal Mounting Bracket
15 Clutch Interlock Switch
KAA5C150
Notice: Assembly should follow the disassembly procedure in the reverse order.
Grease specification: Long - term grease (T/Mn DBL6611.00)
CLUTCH 5C-13
SSANGYONG MY2002
Inspection Procedure
1. Pedal Stroke (A).
Installation Notice
Notice: To adjust the pedal stroke, loosen the lock
nut (H) of the interlock switch (G) and turn the two
lock auto until the stroke is correct.
2. Pedal Height (B).
Installation Notice
Notice: To adjust the pedal height, loosen the lock
nut (C) of the stopper bolt (D) and turn the stopper
bolt until the height is correct.
3. Pedal Free Play (E).
Installation Notice
Notice: To adjust the pedal free play, loosen the
lock nut (F) of the master cylinder and turn the
push rod until the free play is correct.
4. Check the fulcrum pin and the bushing for wear,
the pedal for bending and the spring for damage.
KAA5C160
Max. Stroke
158 mm
Height
(From the Floor Carpet)
147 - 187 mm
Free Play
5 - 10 mm
CLUTCH 5C-15
SSANGYONG MY2002
Replace
Repair or Replace
Replace
Replace
Adjust
Repair or Replace
Replace
Excessive Wear of Facing
Hard or Oily Facing
Damaged Pressure Plate or Flywheel
Damaged or Burnt Diaphragm Spring
Clutch Pedal Free play Insufficient
Faulty Operation of Clutch Pedal
Worn or Damaged Clutch Disc
Action
Checks
DIAGNOSIS
CLUTCH SLIPS
Replace
Repair or Replace
Repair or Replace
Replace
Adjust
Vibration or Excessive Run-out of Disc
Rust or Wear of Disc Spline
Oily Facing
Damaged Diaphragm Spring
Excessive Clutch Pedal Free play
Action
Checks
POOR DISENGAGEMENT
Adjust Pedal Freeplay
Repair Release Cylinder
Repair or Replace
Repair as Necessary
Replace
Excessive Clutch Pedal Free play
Faulty Clutch Release Cylinder
Worn Disc, Excessive Run-out, Damaged Lining
Dirty or Burred Splines on Input Shaft or Clutch Disc
Damaged Clutch Pressure Plate
Action
Checks
HARD TO SHIFT OR WILL NOT SHIFT
Repair or Replace
Replace
Replace
Replace
Replace
Repair or Replace
Tighten or Replace
Oily Facing
Hard or Faulty Facing
Burnt Torsion Spring
Faulty Pressure Plate
Bent Clutch Diaphragm Spring
Hard or Bent Flywheel
Engine Mounts Loose or Burnt Lever
Action
Checks
CLUTCH CHATTERS WHEN STARTING
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