SsangYong Rexton. Service manual — part 569

MANUAL TRANSMISSION 5B-33

SSANGYONG Y200

YAD5B820

YAD5B830

YAD5B840

20. Place the detent spring and offset lever in the

extension housing and push the extension against
the case and shift cover.

21. Completely compress the detent spring.

22. To install the extension housing to the case, apply

sealer to the top two bolts and tighten them and
tighten the 6 bolts.

23. Apply sealer to the back-up lamp switch and drain

plug and tighten them.

24. Using a hammer, install the offset lever-to-shift

roll pin.

25. Turn the transmission case reversely and place a

dial indicator on the extension housing. Move the
input and main shift up and down and measure
end play. Select a shim which is the same
thickness as the measurement ( 0.001 inch). After
shim installation, the end play should be “0”.

26. Remove the input bearing retainer and do the

following :

•

Install the adjusting shim behind the input
bearing outer race in the retainer and if 2 shims
are used, install the thinner one in first.

•

Install the retainer to the case and tighten the
bolts.

•

If end play is not 0change the shim again.

•

Apply RTV sealant to the sealing surface of the
retainer.

•

Apply sealer to the 4 retainer bolts and tighten
them.

SSANGYONG Y200

5B-34 MANUAL TRANSMISSION

27. Remove the fill plug.

28. Remove the transmission from the holding fixture

and install it to the vehicle.

29. Clean the sealing surface of the shift control lever.

30. Install the control cables to the shift lever.

YAD5B850

YAD5B870

YAD5B860

MAIN SHAFT

Disassembly Procedure

1. For correct reassemble, place an alignment mark

on the 3-4 Synchronizer hub and sleeve.

2. Using a hydraulic press and puller plate, remove

the 3-4 Synchronizer assembly and the 3rd speed
gear.

3. Remove the 3rd speed gear bearing and spacer.

4. Using a snap ring pliers, remove the 2nd speed

gear snap ring.

5. Remove the 2nd speed gear thrust washer.

MANUAL TRANSMISSION 5B-35

SSANGYONG Y200

6. Remove the 2nd speed gear, bearing and spacer.

YAD5B880

YAD5B890

YAD5B910

YAD5B900

7. Using a screwdriver, remove the spiral retaining

ring.

8. Remove the thrust washer and three-piece 2nd

speed blocking ring assembly.

9. For correct reassembly, place an alignment mark

on the 1-2 synchronizer hub and sleeve.

10. Remove the 1-2 synchronizer sleeve from the hub

with following parts :

•

The anti-rattle ball and spring.

•

The three keys.

•

One of the 3 springs.

SSANGYONG Y200

5B-36 MANUAL TRANSMISSION

11. Using a hydraulic press and puller plate, remove

the 5th speed driven gear from the main shaft.

YAD5B920

YAD5B930

YAD5B950

YAD5B940

12. Remove the main shaft rear bearing assembly from

the shaft.

13. Remove the 1st speed gear and bearing.

14. Remove the inner race.