SsangYong Rexton. Manual - part 572

MANUAL TRANSMISSION  5B-45

SSANGYONG  Y200

YAD5B1C0

INSPECTION OF COMPONENTS

Inspection Procedure

1. Clean all parts with solvent and dry them with

compressed air. Check the following parts for
cracks and damaged sealing surfaces.

•

Case

•

Extension housing

•

Shift Cover

•

Input bearing retainer

•

Counter shaft rear bearing retainer

2. Check the parts which support bearings and shafts

for excessive wear and replace them if necessary.

YAD5B1D0

YAD5B1B0

3. Check the bearing surfaces of the following parts ;

•

Input shaft

•

Main shaft and its gears

•

Counter shaft and 5th drive gear

4. Check the reverse idler shaft and its gears.

Notice: Replace excessive wear parts and do not
file on the hardened surface and precision ground.

SSANGYONG  Y200

5B-46  MANUAL TRANSMISSION

5. Check the shift mechanism parts as follows :

•

Wear of the shift shaft.

•

Wear of the detent/guide plate and offset lever.

YAD5B1E0

YAD5B1F0

YAD5B1H0

YAD5B1G0

6. Check worn edges on the following parts :

•

Selector arm.

•

Interlock plate.

•

Selector plates for the 1-2 and 3-4 shift forks.

•

5-R shift lever and the rollers on the reverse
fork and the 5th shift rail/fork.

7. Check worn mating surfaces on the following parts :

•

1-2 shift fork, pads and synchronizer sleeve.

•

3-4 shift fork, pads and synchronizer sleeve.

•

5th shift rail/fork pads and synchronizer sleeve.

•

Reverse fork and reverse idler gear sleeve.

MANUAL TRANSMISSION  5B-47

SSANGYONG  Y200

YAD5B1K0

YAD5B1M0

8. Check the following Bearing for excessive war:

•

Crankshaft pilot bushing for the front of the input
shaft.

•

Clutch release bearing.

•

Input shaft bearing.

•

Main shaft pilot bearing rollers.

•

Main shaft thrust Bearing and its surfaces.

•

Speed gear roller bearing on the main shaft.

•

Main shaft rear bearing.

•

Counter shaft front and rear bearings.

YAD5B1L0

YAD5B1J0

9. Check the gear tooth surfaces of all gear sets.

10. Check the reverse gear set surfaces. Check the

surfaces of gear teeth for excessive wear, pitting,
scoring and spalling and replace if necessary.

SSANGYONG  Y200

5B-48  MANUAL TRANSMISSION

11. Take apart the three synchronizer assemblies and

check :

•

The 1-2 synchronizer.

YAD5B1N0

YAD5B1P0

YAD5B1R0

YAD5B1Q0

•

The 5th blocking ring.

12. Check the fit between the hub and sleeve of each

synchronizer

•

Excessively tight or loose hub-to-sleeve fit.

•

Wear of the cone clutch surfaces of brass
blocking rings and gears.

13. Measure the clearance between the blocking ring

and the speed gear

•

New 1-2 blocking ring : 0.87 - 1.4mm

•

New 3-4 blocking ring : 0.88 - 1.5mm

Notice: Excessive wear of the blocking ring or the
speed gear cone surface will cause shift block-
out gear clash.