SsangYong Rexton. Service manual — part 561
SECTION 5B
MANUAL TRANSMISSION
TABLE OF CONTENTS
General Description and Operation . . . . . . 5B-2
Shift Lever . . . . . . . . . . . . . . ... 5B-2
Transmission Assembly . . . . . . . . . ... 5B-2
Specifications . . . . . . . . . . . . . .. 5B-3
Diagnostic Information and Procedures . . . .. 5B-4
Diagnosis Table . . . . . . . . . . . . ... 5B-6
Component Locator . . . . . . . . . . . 5B-7
Cross-Sectional View . . . . . . . . . . ... 5B-7
Power Flow . . . . . . . . . . . . . . .. 5B-8
Seni-Remote Kit Disassembly and Assembly . ... 5B-9
Transmission Assembly . . . . . . . . . . 5B-10
Transmission Assembly Disassembled View . .. 5B-11
Maintenance and Repair . . . . . . . . ... 5B-14
On-Vehicle Service . . . . . . . . . . . ... 5B-14
Semi-Remote Kit . . . . . . . . . . . . 5B-14
Transmission . . . . . . . . . . . . . . 5B-19
Unit Repair . . . . . . . . . . . . . . .. 5B-24
Major Unit . . . . . . . . . . . . . . .. 5B-24
Main Shaft . . . . . . . . . . . . . . . 5B-34
Input Shaft . . . . . . . . . . . . . . 5B-38
Counter Shaft . . . . . . . . . . . . . 5B-40
Extension Housing . . . . . . . . . . . . 5B-40
Shift Cover . . . . . . . . . . . . . . 5B-41
Inspection of Components . . . . . . . . . 5B-45
SSANGYONG Y200
5B-2 MANUAL TRANSMISSION
GENERAL DESCRIPTION AND OPERATION
SHIFT LEVER
The shift lever is a type of linkage connected directly
and lock shifting from 5th to reverse. This unit
decreases the possibility of any blown, wear etc.
YAD5B010
YAD5B020
YAD5B030
TRANSMISSION ASSEMBLY
MANUAL TRANSMISSION 5B-3
SSANGYONG Y200
Model
Type
Gear Ratio
Oil
Weight (Dry)
1st
2nd
3rd
4th
5th
Reverse
Specification
Capacity(litre)
Change Interval
Application
SPECIFICATIONS
T5WC
Floor Change
3.969 : 1
2.341 : 1
1.457 : 1
1.000 : 1
0.851 :1
3.710 : 1
ATF DEXRON II / III
3.4 L
Check : Every 15,000 km,
Replace : Every 50,000 km
33kg
Description
Notice: Add LUBRIZOL (280cc) in oil after overhauling.
SSANGYONG Y200
5B-4 MANUAL TRANSMISSION
DIAGNOSTIC INFORMATION AND PROCEDURES
Control lever assembly broken or dam-
aged.
Damaged offset lever, shift fork, selector
place or selector arm.
Clutch not releasing.
Improper or low transmission oil.
Shift or shift rail binding.
Binding of sliding synchronizers or gears.
If reverse only, faulty backup switch.
Worn or damaged flywheel pilot bushing.
Engine idle speed too high.
Damaged or faulty clutch.
Pilot bearing between input shaft and
output shaft binding.
Damaged synchronizer.
Bell housing misaligned.
Damaged gear(s).
Worn or damaged flywheel pilot bushing.
Loosened transmission or flywheel
housing bolts, improper alignment.
Synchronizer damaged or excessively
worn.
Blocking ring damaged, worn index slots
or friction surfaces worn or damaged.
Excessive countershaft end play.
Worn or damaged fork due to loosened
shaft, rail or shifting fork.
Fork or offset lever loose on shaft or rail.
Worn or damaged forks, offset lever,
shaft or rail.
Replace control lever and housing assem-
bly.
Remove extension, adapter or case
cover. Check or replace damaged parts.
Adjust or replace clutch.
Add or replace with specified oil.
Remove extension, adapter or case
cover. Check or replace damaged parts.
Remove extension, adapter or case
cover. Check synchronizers and gears
and replace damaged parts.
Check or replace backup switch.
Replace pilot bushing.
Adjust idle speed to specified speed.
Adjust or replace clutch.
Replace or check roller bearings.
Check or replace synchronizer parts.
Align bell housing and bore.
Check or replace gear(s).
Replace pilot bushing.
Tighten bolts to specified value. Realign
if necessary.
Check or replace synchronizer parts.
Check or replace blocking ring.
Check worn or damaged parts. Adjust
shim thickness using roller bearings if
necessary.
Check for wear or damaged. Replace
worn or damaged parts.
Replace extension, adapter or case
cover. Check or replace loose parts on
shaft or rail. Replace roll pin(s).
Remove extension, adapter or case
cover. Check for wear or damaged.
Replace damaged parts.
Check
Applicatio
Will not shift
(control lever moves)
Hard shift or control
lever will not move into
gear
Gears crash when
shifting
Transmission jumps
out
Transmission locked in
one gear
Action
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