Daewoo Musso. Manual — part 281

5B-26 MANUAL TRANSMISSION

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 :

l

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.

l

Install the retainer to the case and tighten the bolts.

l

If end play is not ‘0’change the shim again.

l

Apply RTV sealant to the sealing surface of the retainer.

l

Apply sealer to the 4 retainer bolts and tighten them.

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.

MANUAL TRANSMISSION 5B-27

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.

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

5B-28 MANUAL TRANSMISSION

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 :

l

The anti-rattle ball and spring.

l

The three keys.

l

One of the 3 springs.

11. Using a hydraulic press and puller plate, remove the 5th

speed driven gear from the main shaft.

MANUAL TRANSMISSION 5B-29

12. Remove the main shaft rear bearing assembly from the

shaft.

13. Remove the 1st speed gear and bearing.

14. Remove the inner race.

15. Remove the tree-piece 1st speed blocking ring assembly

and remaining synchronizer spring.

16. Check and clean all removed parts and replace if

necessary.