SsangYong Korando II (1996-2006 year). Manual - part 339

SSANGYONG  MY2002

5B-46  MANUAL TRANSMISSION

8. Check the following Bearing for excessive war:

•

Crankshaft pilot bushing for the front of the input
shaft.

•

Clutch release bearing.

•

Input shaft bearing.

•

Main shaft pilot bearing rollers.

•

Main shaft thrust Bearing and its surfaces.

YAD5B1J0

YAD5B1F0

YAD5B1H0

YAD5B1G0

6. Check worn edges on the following parts :

•

Selector arm.

•

Interlock plate.

•

Selector plates for the 1-2 and 3-4 shift forks.

•

5-R shift lever and the rollers on the reverse
fork and the 5th shift rail/fork.

7. Check worn mating surfaces on the following parts :

•

1-2 shift fork, pads and synchronizer sleeve.

•

3-4 shift fork, pads and synchronizer sleeve.

•

5th shift rail/fork pads and synchronizer sleeve.

•

Reverse fork and reverse idler gear sleeve.

MANUAL TRANSMISSION  5B-47

SSANGYONG  MY2002

YAD5B1K0

YAD5B1M0

•

Speed gear roller bearing on the main shaft.

•

Main shaft rear bearing.

•

Counter shaft front and rear bearings.

YAD5B1L0

9. Check the gear tooth surfaces of all gear sets.

10. Check the reverse gear set surfaces. Check the

surfaces of gear teeth for excessive wear, pitting,
scoring and spalling and replace if necessary.

11. Take apart the three synchronizer assemblies and

check :

•

The 1-2 synchronizer.

YAD5B1N0

SSANGYONG  MY2002

5B-48  MANUAL TRANSMISSION

14. Check for gear clash on the synchronizer sleeve

teeth or the clutch teeth on the speed gear.

15. Check the synchronizer sleeve and gear clutch

tooth for hop-out.

YAD5B1S0

YAD5B1P0

YAD5B1R0

YAD5B1Q0

•

The 5th blocking ring.

12. Check the fit between the hub and sleeve of each

synchronizer

•

Excessively tight or loose hub-to-sleeve fit.

•

Wear of the cone clutch surfaces of brass
blocking rings and gears.

13. Measure the clearance between the blocking ring

and the speed gear

•

New 1-2 blocking ring : 0.87 - 1.4mm

•

New 3-4 blocking ring : 0.88 - 1.5mm

Notice: Excessive wear of the blocking ring or the
speed gear cone surface will cause shift block-
out gear clash.

Specifications ....................................................... 5C-2

General Specifications ......................................... 5C-2

Fastener Tightening Specifications ....................... 5C-2

Component Locator ............................................. 5C-3

Clutch Assembly ................................................. 5C-3

Pedal and Master Cylinder ................................... 5C-4

Maintenance and Repair ..................................... 5C-5

On-Vehicle Service ................................................. 5C-5

Bleeding of Clutch System ................................... 5C-5

Clutch Disc ......................................................... 5C- 6

Master Cylinder ................................................. 5C-10

Clutch Pedal ...................................................... 5C-12

Clutch Oil Chamber ........................................... 5C-14

Diagnosis ............................................................ 5C-15

Clutch Slips ....................................................... 5C-15

Poor Disengagement ......................................... 5C-15

Hard to Shift or Will not Shift ............................... 5C-15

Clutch Chatters When Starting ........................... 5C-15

Difficult Pedal Operation .................................... 5C-16

Clutch Noisy ...................................................... 5C-16

Special Tools and Equipment ............................ 5C-17

Special Tools Table ............................................ 5C-17

SECTION 5C

CLUTCH

CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.

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