SsangYong Rexton. Manual - part 567

MANUAL TRANSMISSION  5B-25

SSANGYONG  Y200

7. Remove the offset lever from the extension

housing with the detent ball and spring.

8. Remove the roll pin from either the offset lever or

extension housing.

YAD5B510

YAD5B520

YAD5B540

YAD5B530

9. Remove the counter shaft thrust race and bearing.

10. Carefully remove the oiling funnel from the end of

the counter shaft.

11. Using a 10 mm wrench, remove the 10 bolts from

the shift cover.

Notice: For assembly, note the location of the two
bolts.

12. Lift up the shift cover after sliding it toward the

drain plug about 3 cm. At this time remove sealer
bond.

SSANGYONG  Y200

5B-26  MANUAL TRANSMISSION

13. Using a needle nose pliers, remove the 5th-R lever

clip.

YAD5B550

YAD5B560

YAD5B580

YAD5B570

14. Using a 21 mm wrench or a T-50 bit, remove the

5th-R lever pivot bolt.

Notice: Apply sealer bond to this bolt during
assembly.

15. Using a 22 mm wrench, remove the back-up lamp

switch from the 5-R lever side.

Notice: Apply sealer to the threads.

16. Pull out the 5th-R lever out of the transmission.

17. U s i n g   a   s n a p   r i n g   p l i e r s ,   r e m o v e   t h e   5 t h

synchronizer snap ring from the end of the counter
shaft.

MANUAL TRANSMISSION  5B-27

SSANGYONG  Y200

18. Remove the 5th synchronizer assembly with its

fork and rail assembly from the counter shaft.

YAD5B590

YAD5B600

YAD5B620

YAD5B610

19. Remove the slip yoke snap ring from the main

shaft.

20. Remove the 5th speed drive gear snap ring from

the main shaft.

21. Make alignment marks on the case and input

bearing retainer and remove the 4 input shaft
bearing retainer bolts, using a 13 mm wrench.

Remove the input bearing retainer with the bearing
outer race and shim.

Notice:  Apply sealer on these bolts during
assembly.

SSANGYONG  Y200

5B-28  MANUAL TRANSMISSION

22. Remove the input shaft from the case by rotating

it until the flat surface appears.

23. Remove the following parts from the input shaft.

•

4th speed gear blocking ring.

•

Main shaft thrust race and bearing.

•

Main shaft pilot bearing rollers (15 rollers).

Notice: Be careful not to dissipate the pilot
bearing rollers.

YAD5B630

YAD5B640

YAD5B660

YAD5B650

24. Remove the main shaft in 2 steps.

•

To remove the rear bearing outer race, push the
main shaft rearward.

•

Tilt and lift the main shaft from the case.

25. Remove the reverse fork and spring from the case.