SsangYong Korando II (1996-2006 year). Service manual - part 336

SSANGYONG  MY2002

5B-34  MANUAL TRANSMISSION

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.

YAD5B850

YAD5B870

YAD5B860

MAIN SHAFT

Disassembly Procedure

1. For correct reassemble, place an alignment mark

on the 3-4 Synchronizer hub and sleeve.

2. Using a hydraulic press and puller plate, remove

the 3-4 Synchronizer assembly and the 3rd speed
gear.

3. Remove the 3rd speed gear bearing and spacer.

4. Using a snap ring pliers, remove the 2nd speed

gear snap ring.

5. Remove the 2nd speed gear thrust washer.

MANUAL TRANSMISSION  5B-35

SSANGYONG  MY2002

6. Remove the 2nd speed gear, bearing and spacer.

YAD5B880

YAD5B890

YAD5B910

YAD5B900

7. Using a screwdriver, remove the spiral retaining

ring.

8. Remove the thrust washer and three-piece 2nd

speed blocking ring assembly.

9. For correct reassembly, place an alignment mark

on the 1-2 synchronizer hub and sleeve.

10. Remove the 1-2 synchronizer sleeve from the hub

with following parts :

•

The anti-rattle ball and spring.

•

The three keys.

•

One of the 3 springs.

SSANGYONG  MY2002

5B-36  MANUAL TRANSMISSION

11. Using a hydraulic press and puller plate, remove

the 5th speed driven gear from the main shaft.

YAD5B920

YAD5B930

YAD5B950

YAD5B940

12. Remove the main shaft rear bearing assembly from

the shaft.

13. Remove the 1st speed gear and bearing.

14. Remove the inner race.

MANUAL TRANSMISSION  5B-37

SSANGYONG  MY2002

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.