SsangYong Rexton. Manual - part 570

MANUAL TRANSMISSION  5B-37

SSANGYONG  Y200

YAD5B960

YAD5B970

YAD5B990

15. Remove the tree-piece 1st speed blocking ring

assembly and remaining synchronizer spring.

16. Check and clean all removed parts and replace if

necessary.

Assembly Procedure

1. When assemble the synchronizer, make sure that

the hubs and sleeves are matched and the 3 keys
are installed properly. Also align blocking rings
with keys during installation.

Notice:  Before assembly, coat all parts with
lubricant. In case of the paper-lined blocking rings,
soak them in DexronII/III before installation.

2. Assemble the following parts :

•

1st speed blocking ring.

•

Alignment pin and 1st speed gear bearing race.

•

1st speed gear and its bearing.

3. Install the rear bearing assembly to the main shaft.

YAD5B980

4. Using a hydraulic press and installer, press the

5th  driven gear onto the main shaft. While the
main shaft is still on the press bed, install the 5th
driven gear snap ring. If the snap ring does not fit
completely, continue pressing the 5th driven gear.

SSANGYONG  Y200

5B-38  MANUAL TRANSMISSION

5. Install the following parts :

•

2nd speed blocking ring assembly.

•

Thrust washer for the blocking ring inner cone.

•

Spiral retaining ring (Use special tools).

•

2nd speed gear spacer, bearing and gear.

•

2nd gear thrust washer and snap ring.

•

3rd speed gear spacer, bearing and gear.

•

3rd speed blocking ring.

YAD5B0A0

YAD5B0B0

YAD5B0D0

YAD5B0C0

6. Using a hydraulic press and installer, install the

3-4 synchronizer hub onto the main shaft.

Notice:  Align the blocking ring with the
synchronizer keys while installing the hub.

INPUT SHAFT

Disassembly Procedure

1. Remove the following parts from the input shaft :

•

Main shaft thrust race and bearing.

•

Main shaft pilot bearing rollers (15 rollers).

2. Using a hydraulic press and puller plate, remove

the input shaft bearing assembly from the shaft.

MANUAL TRANSMISSION  5B-39

SSANGYONG  Y200

YAD5B0E0

YAD5B0F0

YAD5B0H0

3. Remove the input bearing.

4. Remove the input shaft seal.

5. Check and clean all removed parts and replace if

necessary.

Assembly Procedure

1. Using a hydraulic press and installer, press the

input shaft bearing onto the input shaft.

2. Apply grease to the thrust bearing inner roller (15

rollers) and install the main shaft thrust bearing
and its race in the rear of the input shaft.

YAD5B0G0

3. Using a rubber hammer and installer, install the

input bearing retainer and input shaft seal after
applying grease.

4. Install the bearing outer race to the retainer without

end play adjusting shim.

SSANGYONG  Y200

5B-40  MANUAL TRANSMISSION

COUNTER SHAFT

Disassembly Procedure

1. Using a hydraulic press and special tool, remove

the front bearing assembly from the counter shaft.

2. Check and clean all removed parts and replace if

necessary.

YAD5B0J0

YAD5B0K0

YAD5B0M0

YAD5B0L0

Assembly Procedure

1. Using a hydraulic press and installer, press the

front bearing assembly onto the counter shaft.

2. Install is as follows :

•

Install a new O-ring on the counter shaft outer
race and lubricate it.

•

Using a installer, lightly tap the race into its
bore until the O-ring is compressed.

•

Install the race to be fully seated on the inside
of the case.

EXTENSION HOUSING

Disassembly Procedure

1. Remove the vent from the extension housing.

2. Remove the O-ring and steel ring from the rear of

the extension housing.

3. Check and clean all removed parts and replace if

necessary.