Daewoo Korando. Manual - part 278

MANUAL TRANSMISSION  5B-25

14. Using a needle nose pliers, install the reverse fork spring

to its pin inside the case. Check the operation of the 5-R
shift mechanism at this time.

15. Using a snap ring piers, install the slip yoke snap ring onto

the end of the main shaft.

16. Make sure that the 1-2 and 3-4 synchronizer sleeves and

5-R shift lever are in neutral position.

17. Align the holes the case and cover with alignment-type

bolts. Tighten the 10 bolts.

18. Apply ‘RTV’ sealant on the sealing surface of the extension

housing.

19. Apply grease on the detent/guide plate in the extension

housing. Install the detent ball in the 3-4 position.

20. Place the detent spring and offset lever in the extension

housing and push the extension against the case and shift
cover.

5B-26  MANUAL TRANSMISSION

21. Completely compress the detent spring.

22. To install the extension housing to the case, apply sealer

to the top two bolts and tighten them and tighten the 6
bolts.

23. Apply sealer to the back-up lamp switch and drain plug

and tighten them.

24. Using a hammer, install the offset lever-to-shift roll pin.

25. Turn the transmission case reversely and place a dial

indicator on the extension housing. Move the input and
main shift up and down and measure end play. Select a
shim which is the same thickness as the measurement (±
0.001 inch). After shim installation, the end play should be
‘0’.

26. Remove the input bearing retainer and do the following :

l

Install the adjusting shim behind the input bearing outer

race in the retainer and if 2 shims are used, install the
thinner one in first.

l

Install the retainer to the case and tighten the bolts.

l

If end play is not ‘0’change the shim again.

l

Apply RTV sealant to the sealing surface of the retainer.

l

Apply sealer to the 4 retainer bolts and tighten them.

27. Remove the fill plug.

28. Remove the transmission from the holding fixture and install

it to the vehicle.

29. Clean the sealing surface of the shift control lever.

30. Install the control cables to the shift lever.

MANUAL TRANSMISSION  5B-27

MAIN SHAFT

Disassembly Procedure

1. For correct reassemble, place an alignment mark on the 3-

4 Synchronizer hub and sleeve.

2. Using a hydraulic press and puller  plate, remove the 3-4

Synchronizer assembly and the 3rd speed gear.

3. Remove the 3rd speed gear bearing and spacer.

4. Using a snap ring pliers, remove the 2nd  speed gear snap

ring.

5. Remove the 2nd  speed gear thrust washer.

6. Remove the 2nd speed gear, bearing and spacer.

5B-28  MANUAL TRANSMISSION

7. Using a screwdriver, remove the spiral retaining ring.

8. Remove the thrust washer and three-piece 2nd speed

blocking ring assembly.

9. For correct reassembly, place an alignment mark on the

1-2 synchronizer hub and sleeve.

10. Remove the 1-2 synchronizer sleeve from the hub with

following parts :

l

The anti-rattle ball and spring.

l

The three keys.

l

One of the 3 springs.

11. Using a hydraulic press and puller plate, remove the 5th

speed driven gear from the main shaft.