SsangYong Korando II (1996-2006 year). Manual - part 337

SSANGYONG  MY2002

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.

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6. Using a hydraulic press and installer, install the

3-4 synchronizer hub onto the main shaft.

Notice:  A l i g n   t h e   b l o c k i n g   r i n g   w i t h   t h e
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  MY2002

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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.

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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  MY2002

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.

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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.

Assembly Procedure

1. Install the O-ring and steel ring to the rear of the

extension housing.

2. Install the vent to the extension housing.

MANUAL TRANSMISSION  5B-41

SSANGYONG  MY2002

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SHIFT COVER

Disassembly Procedure

1. Using a hammer and a pin punch (3/16) remove

the selector arm roll pin.

2. Before removal, note the correct position of the

interlock plate and selector arm and remove the
shift shaft.

3. Check and clean all removed parts and replace if

necessary.

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Assembly Procedure

1. If the shaft cup plug was removed, apply plug

outer surface with sealer and install it into the
cover.

2. Install the fork pads and selector plates onto the

1-2 and 3-4 shift forks.

3. Assemble the sift cover parts as follows :

•

Push the shift shaft into the cover until the front
of the shaft is at the inside of the cover.

•

Install the 1-2 shift fork and its selector plate.

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