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