SsangYong Rexton. Service manual — part 566
MANUAL TRANSMISSION 5B-21
SSANGYONG Y200
Pre-Installation Checks Checking Procedure
1. Separate the clutch release fork from the pivot and
remove the pivot from the clutch housing.
2. Check the pivot. Fork and release bearing.
3. Check the pressure plate spring.
Notice: Inspect each parts and replace the
excessively worn parts.
4. Check the clutch housing alignment as follows :
•
Place the magnetic base on the pressure plate
spring.
•
Check the housing bore alignment.
YAD5B350
YAD5B360
YAD5B370
YAD5B380
- Place the dial indicator on the bore.
- By rotating the crankshaft one revolution,
record the dial indicator reading.
SSANGYONG Y200
5B-22 MANUAL TRANSMISSION
62 - 93 N•m
(45 - 69 lb-ft)
21 - 35 N•m
(15 - 26 lb-ft)
•
Check the housing face alignment.
- Place the dial indicator on the housing face.
- By rotating the crankshaft one revolution,
record the dial indicator reading.
Notice: If the reading is greater than 0.010 inch,
insert the shim between the engine and clutch
housing and adjust the alignment.
5. Check the following parts :
•
Pressure plate spring assembly
•
Disc
•
Flywheel
•
Input shaft pilot bearing
Notice: Replace the excessively worn parts.
6. Lubricate the clutch release bearing bore, fork
pivot head during assembly.
Installation Procedure
1. Install the transmission to the vehicle. At this time,
seat correctly the input shaft of the transmission
on the pilot bearing of the flywheel.
2. Tighten the transmission mounting bolts as the
specified torque on the vehicle.
Installation Notice
YAD5B390
YAD5B400
YAD5B410
YAD5B420
Tightening Torque
77 - 87 N•m
(57 - 64 lb-ft)
3. Install the cross member and tighten as the
specified torque by supporting the suitable jack.
Installation Notice
Tightening
Torque
Left/Right
Center
MANUAL TRANSMISSION 5B-23
SSANGYONG Y200
4. Install the front and rear propeller shafts to the
transmission.
Installation Notice
5. Connect the cable, the harness and the bleeder.
6. Install the back lamp switch.
7. Install the speedometer cable.
YAD5B430
YAD5B440
YAD5B450
YAD5B310
81 - 89 N•m
(60 - 66 lb-ft)
70 - 90 N•m
(52 - 66 lb-ft)
Tightening
Torque
Front
Rear
8. Charge the approved oil in the transmission
housing and tighten the drain plug and the filler
plug.
Installation Notice
•
Oil
25 N•m (18 lb-ft)
25 N•m (18 lb-ft)
Tightening
Torque
Filler Plug
Drain Plug
Spec.
Capacity
3.4L
2.0L
4WD
2WD
ATF Dexron II
SSANGYONG Y200
5B-24 MANUAL TRANSMISSION
UNIT REPAIR
MAJOR UNIT
Disassembly Procedure
1. Remove the shift lever from the extension housing.
YAD5B470
YAD5B480
YAD5B500
YAD5B490
2. Install the removed transmission into a fixture.
3. Remove the drain plug and drain the oil. Using a
10 mm wrench, remove the clamp bolt and position
the offset lever in the 3-4 position of neutral.
Notice: Removal of the offset lever in a position
other than 3-4 of neutral will be difficult.
4. Using a pin punch and a hammer, remove the roll
pin to remove the shift lever from the offset lever.
5. Using a 15 mm wrench, remove the 8 bolts from
the extension housing.
6. Separate the extension housing from the case and
shift cover.
Separate the offset lever from the shift.
Notice: Do not remove the offset lever while the
extension housing is still assembled to the case.
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