SsangYong Stavic / SsangYong Rodius (2005 year). Manual — part 337
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
46
TSM54/52 MANUAL TRANSMISSION
STAVIC - 2004.09
4B
Synchronizer
outer ring
Synchronizer
intermediate
cone
Synchronizer
under ring
Synchronizer
under ring
Synchronizer
intermediate
cone
Synchronizer
outer ring
32. Remove the 1/2 gear synchronizer hub along with double
synchronizer sleeve.
30. Remove the inner race and 1st gear from 1st gear, and
remove the needle bearing from the shaft.
33. Remove the synchronizer inner intermediate cone and
outer ring in 2nd gear side.
31. Remove the synchronizer inner intermediate cone and
outer ring in 1st gear side.
[Notice]
Store the disassembled gears by relevant components.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
47
TSM54/52 MANUAL TRANSMISSION
STAVIC - 2004.09
4B
34. Remove the 2nd gear and needle bearing.
35. Remove the oil seal from the extension housing.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
48
TSM54/52 MANUAL TRANSMISSION
STAVIC - 2004.09
4B
3. INSPECTION BEFORE REASSEMBLY
1. Clean all the disassembled components with solvent and
dry them with compressed air.
Check the components for crack, wear and damage.
• Case, extension housing, shift lever
• Input bearing retainer
• Counter shaft rear bearing retainer
2. Check the bearing and shaft supporting area for wear
and replace if needed.
5. Check the following components for wear:
• Selector arm
• Interlock plate
• 1/2 and 3/4 shift fork
• Shift shaft
• Detent/guide plate and offset lever
• Each shift lever shift fork
3. Check the surface conditions on:
• Input shaft
• Main shaft and gears
• Counter shaft and 5th drive gear
4. Reverse idler shaft and gears
[Notice]
Replace the excessively worn components. Do not grind the
precisely machined components.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
49
TSM54/52 MANUAL TRANSMISSION
STAVIC - 2004.09
4B
6. Check the following components for excessive wear:
• Crankshaft bushing in front of input shaft
• Clutch release bearing
• Main shaft pilot bearing roller
• Main shaft thrust bearing mating surface
• Main shaft speed gear roller bearing
• Main shaft rear bearing
• Counter shaft front and rear bearing
7. Check the gear sets for wear in teeth surface.
8. Check the gear sets for excessive wear, crack and break
and replace if needed.
• Hub and sleeve
• 1/2 shift fork, pads, synchronizer sleeve
• 3/4 shift fork, pads, synchronizer sleeve
• 5th gear shift rail/fork, pads, synchronizer sleeve
• Reverse fork and reverse idler gear sleeve
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