SSANGYONG KORANDO 1997 Service Repair Manual

MANUAL TRANSMISSION 5B-23
SSANGYONG MY2002
4. Install the front and rear propeller shafts to the
transmission.
Installation Notice
5. Connect the cable, the harness and the bleeder.
6. Install the back lamp switch.
7. Install the speedometer cable.
YAD5B430
YAD5B440
YAD5B450
YAD5B310
81 - 89 Nm
(60 - 66 lb-ft)
70 - 90 Nm
(52 - 66 lb-ft)
Tightening
TorqueFront
Rear
8. Charge the approved oil in the transmission
housing and tighten the drain plug and the filler
plug.
Installation Notice
Oil25 Nm (18 lb-ft)
25 Nm (18 lb-ft)
Tightening
TorqueFiller Plug
Drain Plug
Spec.
Capacity
3.4L
2.0L
4WD
2WDATF Dexron II

SSANGYONG MY2002
5B-24 MANUAL TRANSMISSION
UNIT REPAIR
MAJOR UNIT
Disassembly Procedure
1. Remove the shift lever from the extension housing.
YAD5B470
YAD5B480
YAD5B500
YAD5B490
2. Install the removed transmission into a fixture.
3. Remove the drain plug and drain the oil. Using a
10 mm wrench, remove the clamp bolt and position
the offset lever in the 3-4 position of neutral.
Notice: Removal of the offset lever in a position
other than 3-4 of neutral will be difficult.
4. Using a pin punch and a hammer, remove the roll
pin to remove the shift lever from the offset lever.
5. Using a 15 mm wrench, remove the 8 bolts from
the extension housing.
6. Separate the extension housing from the case and
shift cover.
Separate the offset lever from the shift.
Notice: Do not remove the offset lever while the
extension housing is still assembled to the case.

MANUAL TRANSMISSION 5B-25
SSANGYONG MY2002
7. Remove the offset lever from the extension
housing with the detent ball and spring.
8. Remove the roll pin from either the offset lever or
extension housing.
YAD5B510
YAD5B520
YAD5B540
YAD5B530
9. Remove the counter shaft thrust race and bearing.
10. Carefully remove the oiling funnel from the end of
the counter shaft.
11. Using a 10 mm wrench, remove the 10 bolts from
the shift cover.
Notice: For assembly, note the location of the two
bolts.
12. Lift up the shift cover after sliding it toward the
drain plug about 3 cm. At this time remove sealer
bond.

SSANGYONG MY2002
5B-26 MANUAL TRANSMISSION
13. Using a needle nose pliers, remove the 5th-R lever
clip.
YAD5B550
YAD5B560
YAD5B580
YAD5B570
14. Using a 21 mm wrench or a T-50 bit, remove the
5th-R lever pivot bolt.
Notice: Apply sealer bond to this bolt during
assembly.
15. Using a 22 mm wrench, remove the back-up lamp
switch from the 5-R lever side.
Notice: Apply sealer to the threads.
16. Pull out the 5th-R lever out of the transmission.
17. Using a snap ring pliers, remove the 5th
synchronizer snap ring from the end of the counter
shaft.

MANUAL TRANSMISSION 5B-27
SSANGYONG MY2002
18. Remove the 5th synchronizer assembly with its
fork and rail assembly from the counter shaft.
YAD5B590
YAD5B600
YAD5B620
YAD5B610
19. Remove the slip yoke snap ring from the main
shaft.
20. Remove the 5th speed drive gear snap ring from
the main shaft.
21. Make alignment marks on the case and input
bearing retainer and remove the 4 input shaft
bearing retainer bolts, using a 13 mm wrench.
Remove the input bearing retainer with the bearing
outer race and shim.
Notice: Apply sealer on these bolts during
assembly.

SSANGYONG MY2002
5B-28 MANUAL TRANSMISSION
22. Remove the input shaft from the case by rotating
it until the flat surface appears.
23. Remove the following parts from the input shaft.
4th speed gear blocking ring.
Main shaft thrust race and bearing.
Main shaft pilot bearing rollers (15 rollers).
Notice: Be careful not to dissipate the pilot
bearing rollers.
YAD5B630
YAD5B640
YAD5B660
YAD5B650
24. Remove the main shaft in 2 steps.
To remove the rear bearing outer race, push the
main shaft rearward.
Tilt and lift the main shaft from the case.
25. Remove the reverse fork and spring from the case.

MANUAL TRANSMISSION 5B-29
SSANGYONG MY2002
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 MY2002
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 Nm (15 lb-ft)

MANUAL TRANSMISSION 5B-31
SSANGYONG MY2002
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 Nm (15 lb-ft)
Tightening Torque 20 Nm (15 lb-ft)

SSANGYONG MY2002
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 Nm (21 lb-ft)
Tightening Torque 15 Nm (11 lb-ft)