SsangYong Korando II (1996-2006 year). Manual - part 335

SSANGYONG  MY2002

5B-30  MANUAL TRANSMISSION

Assembly Procedure

1. Using a hydraulic press and a supporting tool,

press the counter shaft rear bearing into the case.
Be sure that the supporting tool inside of the case
should support the counter shaft.

YAD5B710

YAD5B720

YAD5B740

YAD5B730

2. Without the shim, install the retainer and counter

shaft rear bearing outer race. Tighten the 4 retainer
bolts.

Installation Notice

3. Place a dial indicator on the case and measure

counter shaft end play by moving up and down.

4. Select a shim which is the same thickness as the

indicator rearing (up to 0.004 inch) and assemble
it.

5. When the end play is correctly adjusted, remove

the counter shaft rear bearing retainer and outer
race.

6. Using a pin punch and rubber hammer, install the

reverse idler shaft, gear and O-ring.

Tightening Torque

20 N•m (15 lb-ft)

MANUAL TRANSMISSION  5B-31

SSANGYONG  MY2002

7. Install the counter shaft rear bearing outer race,

shim and retainer.

Installation Notice

Notice: Using a punch and hammer, bend the lock
tabs on the retainer.

YAD5B750

YAD5B760

YAD5B770

8. Install the following parts :

•

Install the main shaft into case.

•

Install the main shaft rear bearing outer race
into the rear of the case.

•

Install the 4th speed blocking ring onto the front
of the main shaft.

•

Install the input shaft onto the front of the main
shaft.

•

Install the input bearing retainer without shim
onto the front of the case.

•

Using a torque wrench, tighten the 4 bolts.

Installation Notice

9. Install the 5th speed drive gear and blocking ring

on the counter shaft.

10. Install the 5th synchronizer and rail/fork.

11. Install the 5th synchronizer snap ring and oiling

funnel.

Tightening Torque

20 N•m (15 lb-ft)

Tightening Torque

20 N•m (15 lb-ft)

SSANGYONG  MY2002

5B-32  MANUAL TRANSMISSION

12. Align the slots of the lever with the rollers of the

reverse fork and 5th shift rail. Apply sealer on the
5-R lever pivot bolt and install it into the case.

Installation Notice

13. Using a needle nose pliers, install the 5-R lever

clip.

YAD5B780

YAD5B790

YAD5B810

YAD5B800

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.

Installation Notice

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.

Tightening Torque

28 N•m (21 lb-ft)

Tightening Torque

15 N•m (11 lb-ft)

MANUAL TRANSMISSION  5B-33

SSANGYONG  MY2002

YAD5B820

YAD5B830

YAD5B840

20. Place the detent spring and offset lever in the

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

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 :

•

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.

•

Install the retainer to the case and tighten the
bolts.

•

If end play is not 0change the shim again.

•

Apply RTV sealant to the sealing surface of the
retainer.

•

Apply sealer to the 4 retainer bolts and tighten
them.