SsangYong Stavic / SsangYong Rodius (2005 year). Manual — part 331

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

22

TSM54/52 MANUAL TRANSMISSION

STAVIC - 2004.09

4B

Thrust Ring (Washer)

When the driving force from engine is transmitted to the output shaft of transmission, each shaft and gear assembly
receives the axial force and this force acts as a resistance to rotating gears.

Lubrication

Transmission oil: ATF DEXRON II or III

Initial installation for taper roller bearing and needle roller bearing, lubrication for shift rail: MoS2 Grease

Counter gear assembly

Input shaft

Thrust ring 1

3/4

synchronizer

1/2

synchronizer

5/R

synchronizer

Output shaft

Thrust washer

Thrust washer

5th

gear

Reverse

gear

1st

gear

2nd

gear

3rd

gear

Head set

gear

Oil level

Oil drain screw

Installation Notice

Sealant on oil drain screw during installation: Loctite DRI LOC 200

Tightening torque: 40 ~ 50 Nm

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AFFECTED VIN

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STAVIC - 2004.09

4B

1. Oil filler plug

2. Air vent

4WD

2WD

[Notice]

Sealant on oil drain screw during installation: Loctite DRI LOC 200

Tightening torque: 40 ~ 50 Nm

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

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TSM54/52 MANUAL TRANSMISSION

STAVIC - 2004.09

4B

5. DIAGNOSTIC INFORMATION AND PROCEDURES

Trouble Diagnosis

Control lever assembly broken or damaged.

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 assembly.

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 dam-

aged parts.

Cause

Symptom

Will not shift

(control lever moves)

Hard shift or control lever

will not move into gear

Gears crash when shift-

ing

Transmission jumps out

Transmission locked in

one gear

Action

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

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TSM54/52 MANUAL TRANSMISSION

STAVIC - 2004.09

4B

Action

Cause

Symptom

Check worn or damaged synchronizer parts

and replace if necessary.

Check worn or damaged gears and replace

if necessary.

Add or drain and replace with proper oil.

Tighten as specified.

Realign correctly.

Check bearings, bearing rollers and parts for

wear or damage. Replace if necessary.

Check for worn or damaged gears(including

speedometer gear). Replace if necessary.

Clean all exposed surfaces, then check for

leaks.

Clean or replace vent or breather.

Check oil level.

Tighten as specified.

Clean leaking surfaces. Reapply sealant.

Replace oil seal.

Worn or damaged synchronizer.

Worn or damaged gears.

Improper or low transmission oil.

Loose bolts or other attaching parts.

Improper flywheel housing to engine crank-

shaft alignment.

Noisy transmission bearing.

Noisy gears.

Leakage from transmission.

Vent or breather clogged.

Too much oil.

Loose bolts at sealing faces.

Improperly applied sealant.

Worn or damaged oil seal.

Transmission locked in

one gear

Transmission noise

Transmission leakage