SsangYong Rexton. Manual — part 568
MANUAL TRANSMISSION 5B-29
SSANGYONG Y200
26. Remove the counter shaft as follows:
•
Using a punch and hammer, pry up the lock
tabs.
•
Using a 13 mm wrench or T-40 bit, remove the
4 bolts.
•
Remove the retainer and shim from the case.
•
Push the counter shaft rearward to remove the
rear bearing outer race.
YAD5B670
YAD5B680
YAD5B700
YAD5B690
27. Using a pin punch and a hammer, remove the roll
pin fixed on the reverse idler shaft.
28. By pushing the reverse idler shaft rearward and
out of the case, remove the reverse idler gear and
O-ring.
29. Using a puller, remove the rear bearing assembly
from the counter shaft.
SSANGYONG Y200
5B-30 MANUAL TRANSMISSION
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.
YAD5B710
YAD5B720
YAD5B740
YAD5B730
2. Without the shim, install the retainer and counter
shaft rear bearing outer race. Tighten the 4 retainer
bolts.
Installation Notice
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 N•m (15 lb-ft)
MANUAL TRANSMISSION 5B-31
SSANGYONG Y200
7. Install the counter shaft rear bearing outer race,
shim and retainer.
Installation Notice
Notice: Using a punch and hammer, bend the lock
tabs on the retainer.
YAD5B750
YAD5B760
YAD5B770
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.
Installation Notice
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.
Tightening Torque
20 N•m (15 lb-ft)
Tightening Torque
20 N•m (15 lb-ft)
SSANGYONG Y200
5B-32 MANUAL TRANSMISSION
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.
Installation Notice
13. Using a needle nose pliers, install the 5-R lever
clip.
YAD5B780
YAD5B790
YAD5B810
YAD5B800
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.
Installation Notice
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.
Tightening Torque
28 N•m (21 lb-ft)
Tightening Torque
15 N•m (11 lb-ft)
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