SsangYong Musso. Manual - part 495

MANUAL TRANSMISSION  5B-27

MAIN SHAFT

Disassembly Procedure

1. For correct reassemble, place an alignment mark on the 3-

4 Synchronizer hub and sleeve.

2. Using a hydraulic press and puller  plate, remove the 3-4

Synchronizer assembly and the 3rd speed gear.

3. Remove the 3rd speed gear bearing and spacer.

4. Using a snap ring pliers, remove the 2nd  speed gear snap

ring.

5. Remove the 2nd  speed gear thrust washer.

6. Remove the 2nd speed gear, bearing and spacer.

5B-28  MANUAL TRANSMISSION

7. Using a screwdriver, remove the spiral retaining ring.

8. Remove the thrust washer and three-piece 2nd speed

blocking ring assembly.

9. For correct reassembly, place an alignment mark on the

1-2 synchronizer hub and sleeve.

10. Remove the 1-2 synchronizer sleeve from the hub with

following parts :

!

The anti-rattle ball and spring.

!

The three keys.

!

One of the 3 springs.

11. Using a hydraulic press and puller plate, remove the 5th

speed driven gear from the main shaft.

MANUAL TRANSMISSION  5B-29

12. Remove the main shaft rear bearing assembly from the

shaft.

13. Remove the 1st speed gear and bearing.

14. Remove the inner race.

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.

5B-30  MANUAL TRANSMISSION

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 Dexron

II

/

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.

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.

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.