SsangYong Stavic / SsangYong Rodius (2005 year). Manual - part 338

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

50

TSM54/52 MANUAL TRANSMISSION

STAVIC - 2004.09

4B

10. Measure the clearance between blocking ring and speed

gear.

• New 1/2 gear blocking ring: 1.1 ~ 1.5 mm

• New 3/4 gear blocking ring: 1.1 ~ 1.5 mm

11. Check the speed gear clutch and synchronizer sleeve

for damage in teeth surface.

12. Check the engagement of synchronizer sleeve and speed

gear clutch.

9. Check the conditions of each synchronizer sleeve and

hub.

• Engagement of hub and sleeve

• Wear on cone clutch surface in blocking ring (brass)

engaging the gears

 [Notice]

If the clearance is excessive, replace it with new one. Otherwise,
it may cause the missing or breakage of the gears.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

51

TSM54/52 MANUAL TRANSMISSION

STAVIC - 2004.09

4B

4. REASSEMBLY

2. Install the 2nd gear and synchronizer outer ring,

intermediate cone and inner ring in regular sequence.

3. Insert three keys into 1/2 synchronizer hub and double

synchronizer sleeve. Install the synchronizer spring in
offset so that it should not be missed out.

Groove

No step

1. Install the 2nd gear needle bearing.

 [Notice]

The 1st/2nd/3rd gear needle bearings have one bearing row
and the sizes of them are same. The reverse needle bearing
has two bearing rows. The 5th needle bearing is smaller than
others and consists of two bearings.

 [Notice]

1/2 gear double synchronizer sleeve doesn’t have a step at
edge, however, 3/4 and 5/R gears have it.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

52

TSM54/52 MANUAL TRANSMISSION

STAVIC - 2004.09

4B

5. Install the synchronizer outer ring, intermediate cone and

inner ring in regular sequence.

4. Install the 1/2 synchronizer hub and double synchronizer

sleeve into the output shaft by using a press.

6. Install the 1st gear.

7. Install the 1st gear needle bearing.

 [Notice]

Make sure that the hub groove faces to 2nd gear. Align the
synchronizer key and the synchronizer ring groove in 2nd
gear.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

53

TSM54/52 MANUAL TRANSMISSION

STAVIC - 2004.09

4B

9. Install the main taper roller bearing by using a press.

8. Install the 1st gear inner race by using a press.

10. Install the reverse fear inner race by using a press.

11. Place the output shaft assembly with the 1st gear facing

downward and install the 3rd gear.

 [Notice]

The 1st inner race doesn’t have a step at edge.

 [Notice]

The reverse gear inner race has a step at edge.