SsangYong Musso. Manual — part 494
MANUAL TRANSMISSION 5B-23
Assembly Procedure
1. Using a hydraulic press and a supporting tool, press the
counter shaft rear bearing into the case. Be sure that the
supporting tool inside of the case should support the counter
shaft.
2. Without the shim, install the retainer and counter shaft rear
bearing outer race. Tighten the 4 retainer bolts.
3. Place a dial indicator on the case and measure counter
shaft end play by moving up and down.
4. Select a shim which is the same thickness as the indicator
rearing (up to 0.004 inch) and assemble it.
5. When the end play is correctly adjusted, remove the counter
shaft rear bearing retainer and outer race.
6. Using a pin punch and rubber hammer, install the reverse
idler shaft, gear and O-ring.
Tightening Torque
20 Nm
5B-24 MANUAL TRANSMISSION
7. Install the counter shaft rear bearing outer race, shim and
retainer.
Tightening Torque
39 - 52 Nm
!
Using a punch and hammer, bend the lock tabs on the
retainer.
8. Install the following parts :
!
Install the main shaft into case.
!
Install the main shaft rear bearing outer race into the
rear of the case.
!
Install the 4th speed blocking ring onto the front of the
main shaft.
!
Install the input shaft onto the front of the main shaft.
!
Install the input bearing retainer without shim onto the
front of the case.
!
Using a torque wrench, tighten the 4 bolts.
9. Install the 5th speed drive gear and blocking ring on the
counter shaft.
10. Install the 5th synchronizer and rail/fork.
11. Install the 5th synchronizer snap ring and oiling funnel.
12. Align the slots of the lever with the rollers of the reverse
fork and 5th shift rail. Apply sealer on the 5-R lever pivot
bolt and install it into the case.
Tightening Torque
28 Nm
13. Using a needle nose pliers, install the 5-R lever clip.
MANUAL TRANSMISSION 5B-25
14. Using a needle nose pliers, install the reverse fork spring
to its pin inside the case. Check the operation of the 5-R
shift mechanism at this time.
15. Using a snap ring piers, install the slip yoke snap ring onto
the end of the main shaft.
16. Make sure that the 1-2 and 3-4 synchronizer sleeves and
5-R shift lever are in neutral position.
17. Align the holes the case and cover with alignment-type
bolts. Tighten the 10 bolts.
18. Apply ‘RTV’ sealant on the sealing surface of the extension
housing.
19. Apply grease on the detent/guide plate in the extension
housing. Install the detent ball in the 3-4 position.
20. Place the detent spring and offset lever in the extension
housing and push the extension against the case and shift
cover.
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 :
!
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 ‘0’change the shim again.
!
Apply RTV sealant to the sealing surface of the retainer.
!
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.
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