SsangYong Stavic / SsangYong Rodius (2005 year). Manual - part 337

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

46

TSM54/52 MANUAL TRANSMISSION

STAVIC - 2004.09

4B

Synchronizer
outer ring

Synchronizer
intermediate
cone

Synchronizer

under ring

Synchronizer
under ring

Synchronizer
intermediate
cone

Synchronizer

outer ring

32. Remove the 1/2 gear synchronizer hub along with double

synchronizer sleeve.

30. Remove the inner race and 1st gear from 1st gear, and

remove the needle bearing from the shaft.

33. Remove the synchronizer inner intermediate cone and

outer ring in 2nd gear side.

31. Remove the synchronizer inner intermediate cone and

outer ring in 1st gear side.

 [Notice]

Store the disassembled gears by relevant components.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

47

TSM54/52 MANUAL TRANSMISSION

STAVIC - 2004.09

4B

34. Remove the 2nd gear and needle bearing.

35. Remove the oil seal from the extension housing.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

48

TSM54/52 MANUAL TRANSMISSION

STAVIC - 2004.09

4B

3. INSPECTION BEFORE REASSEMBLY

1. Clean all the disassembled components with solvent and

dry them with compressed air.

Check the components for crack, wear and damage.

• Case, extension housing, shift lever

• Input bearing retainer

• Counter shaft rear bearing retainer

2. Check the bearing and shaft supporting area for wear

and replace if needed.

5. Check the following components for wear:

• Selector arm

• Interlock plate

• 1/2 and 3/4 shift fork

• Shift shaft

• Detent/guide plate and offset lever

• Each shift lever shift fork

3. Check the surface conditions on:

• Input shaft

• Main shaft and gears

• Counter shaft and 5th drive gear

4. Reverse idler shaft and gears

 [Notice]

Replace the excessively worn components. Do not grind the
precisely machined components.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

49

TSM54/52 MANUAL TRANSMISSION

STAVIC - 2004.09

4B

6. Check the following components for excessive wear:

• Crankshaft bushing in front of input shaft

• Clutch release bearing

• Main shaft pilot bearing roller

• Main shaft thrust bearing mating surface

• Main shaft speed gear roller bearing

• Main shaft rear bearing

• Counter shaft front and rear bearing

7. Check the gear sets for wear in teeth surface.

8. Check the gear sets for excessive wear, crack and break

and replace if needed.

• Hub and sleeve

• 1/2 shift fork, pads, synchronizer sleeve

• 3/4 shift fork, pads, synchronizer sleeve

• 5th gear shift rail/fork, pads, synchronizer sleeve

• Reverse fork and reverse idler gear sleeve