SsangYong Rexton. Manual — part 570
MANUAL TRANSMISSION 5B-37
SSANGYONG Y200
YAD5B960
YAD5B970
YAD5B990
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.
Assembly Procedure
1. When assemble the synchronizer, make sure that
the hubs and sleeves are matched and the 3 keys
are installed properly. Also align blocking rings
with keys during installation.
Notice: Before assembly, coat all parts with
lubricant. In case of the paper-lined blocking rings,
soak them in DexronII/III before installation.
2. Assemble the following parts :
•
1st speed blocking ring.
•
Alignment pin and 1st speed gear bearing race.
•
1st speed gear and its bearing.
3. Install the rear bearing assembly to the main shaft.
YAD5B980
4. Using a hydraulic press and installer, press the
5th driven gear onto the main shaft. While the
main shaft is still on the press bed, install the 5th
driven gear snap ring. If the snap ring does not fit
completely, continue pressing the 5th driven gear.
SSANGYONG Y200
5B-38 MANUAL TRANSMISSION
5. Install the following parts :
•
2nd speed blocking ring assembly.
•
Thrust washer for the blocking ring inner cone.
•
Spiral retaining ring (Use special tools).
•
2nd speed gear spacer, bearing and gear.
•
2nd gear thrust washer and snap ring.
•
3rd speed gear spacer, bearing and gear.
•
3rd speed blocking ring.
YAD5B0A0
YAD5B0B0
YAD5B0D0
YAD5B0C0
6. Using a hydraulic press and installer, install the
3-4 synchronizer hub onto the main shaft.
Notice: Align the blocking ring with the
synchronizer keys while installing the hub.
INPUT SHAFT
Disassembly Procedure
1. Remove the following parts from the input shaft :
•
Main shaft thrust race and bearing.
•
Main shaft pilot bearing rollers (15 rollers).
2. Using a hydraulic press and puller plate, remove
the input shaft bearing assembly from the shaft.
MANUAL TRANSMISSION 5B-39
SSANGYONG Y200
YAD5B0E0
YAD5B0F0
YAD5B0H0
3. Remove the input bearing.
4. Remove the input shaft seal.
5. Check and clean all removed parts and replace if
necessary.
Assembly Procedure
1. Using a hydraulic press and installer, press the
input shaft bearing onto the input shaft.
2. Apply grease to the thrust bearing inner roller (15
rollers) and install the main shaft thrust bearing
and its race in the rear of the input shaft.
YAD5B0G0
3. Using a rubber hammer and installer, install the
input bearing retainer and input shaft seal after
applying grease.
4. Install the bearing outer race to the retainer without
end play adjusting shim.
SSANGYONG Y200
5B-40 MANUAL TRANSMISSION
COUNTER SHAFT
Disassembly Procedure
1. Using a hydraulic press and special tool, remove
the front bearing assembly from the counter shaft.
2. Check and clean all removed parts and replace if
necessary.
YAD5B0J0
YAD5B0K0
YAD5B0M0
YAD5B0L0
Assembly Procedure
1. Using a hydraulic press and installer, press the
front bearing assembly onto the counter shaft.
2. Install is as follows :
•
Install a new O-ring on the counter shaft outer
race and lubricate it.
•
Using a installer, lightly tap the race into its
bore until the O-ring is compressed.
•
Install the race to be fully seated on the inside
of the case.
EXTENSION HOUSING
Disassembly Procedure
1. Remove the vent from the extension housing.
2. Remove the O-ring and steel ring from the rear of
the extension housing.
3. Check and clean all removed parts and replace if
necessary.
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