SsangYong Rexton. Manual - part 566

MANUAL TRANSMISSION  5B-21

SSANGYONG  Y200

Pre-Installation Checks Checking Procedure

1. Separate the clutch release fork from the pivot and

remove the pivot from the clutch housing.

2. Check the pivot. Fork and release bearing.

3. Check the pressure plate spring.

Notice:  Inspect each parts and replace the
excessively worn parts.

4. Check the clutch housing alignment as follows :

•

Place the magnetic base on the pressure plate
spring.

•

Check the housing bore alignment.

YAD5B350

YAD5B360

YAD5B370

YAD5B380

- Place the dial indicator on the bore.

- By rotating the crankshaft one revolution,

record the dial indicator reading.

SSANGYONG  Y200

5B-22  MANUAL TRANSMISSION

62 - 93 N•m

(45 - 69 lb-ft)

21 - 35 N•m

(15 - 26 lb-ft)

•

Check the housing face alignment.

- Place the dial indicator on the housing face.

- By rotating the crankshaft one revolution,

record the dial indicator reading.

Notice: If the reading is greater than 0.010 inch,
insert the shim between the engine and clutch
housing and adjust the alignment.

5. Check the following parts :

•

Pressure plate spring assembly

•

Disc

•

Flywheel

•

Input shaft pilot bearing

Notice: Replace the excessively worn parts.

6. Lubricate the clutch release bearing bore, fork

pivot head during assembly.

Installation Procedure

1. Install the transmission to the vehicle. At this time,

seat correctly the input shaft of the transmission
on the pilot bearing of the flywheel.

2. Tighten the transmission mounting bolts as the

specified torque on the vehicle.

Installation Notice

YAD5B390

YAD5B400

YAD5B410

YAD5B420

Tightening Torque

77 - 87 N•m

(57 - 64 lb-ft)

3. Install the cross member and tighten as the

specified torque by supporting the suitable jack.

Installation Notice

Tightening

Torque

Left/Right

Center

MANUAL TRANSMISSION  5B-23

SSANGYONG  Y200

4. Install the front and rear propeller shafts to the

transmission.

Installation Notice

5. Connect the cable, the harness and the bleeder.

6. Install the back lamp switch.

7. Install the speedometer cable.

YAD5B430

YAD5B440

YAD5B450

YAD5B310

81 - 89 N•m

(60 - 66 lb-ft)

70 - 90 N•m

(52 - 66 lb-ft)

Tightening

Torque

Front

Rear

8. Charge the approved oil in the transmission

housing and tighten the drain plug and the filler
plug.

Installation Notice

•

Oil

25 N•m (18 lb-ft)

25 N•m (18 lb-ft)

Tightening

Torque

Filler Plug

Drain Plug

Spec.

Capacity

3.4L

2.0L

4WD

2WD

ATF Dexron II

SSANGYONG  Y200

5B-24  MANUAL TRANSMISSION

UNIT REPAIR

MAJOR UNIT

Disassembly Procedure

1. Remove the shift lever from the extension housing.

YAD5B470

YAD5B480

YAD5B500

YAD5B490

2. Install the removed transmission into a fixture.

3. Remove the drain plug and drain the oil. Using a

10 mm wrench, remove the clamp bolt and position
the offset lever in the 3-4 position of neutral.

Notice: Removal of the offset lever in a position
other than 3-4 of neutral will be difficult.

4. Using a pin punch and a hammer, remove the roll

pin to remove the shift lever from the offset lever.

5. Using a 15 mm wrench, remove the 8 bolts from

the extension housing.

6. Separate the extension housing from the case and

shift cover.

Separate the offset lever from the shift.

Notice: Do not remove the offset lever while the
extension housing is still assembled to the case.