SSANGYONG KORANDO 1997 Service Repair Manual

MANUAL TRANSMISSION 5B-33
SSANGYONG MY2002
YAD5B820
YAD5B830
YAD5B840
20. Place the detent spring and offset lever in the
extension housing and push the extension against
the case and shift cover.
21. Completely compress the detent spring.
22. To install the extension housing to the case, apply
sealer to the top two bolts and tighten them and
tighten the 6 bolts.
23. Apply sealer to the back-up lamp switch and drain
plug and tighten them.
24. Using a hammer, install the offset lever-to-shift
roll pin.
25. Turn the transmission case reversely and place a
dial indicator on the extension housing. Move the
input and main shift up and down and measure
end play. Select a shim which is the same
thickness as the measurement ( 0.001 inch). After
shim installation, the end play should be “0”.
26. Remove the input bearing retainer and do the
following :
Install the adjusting shim behind the input
bearing outer race in the retainer and if 2 shims
are used, install the thinner one in first.
Install the retainer to the case and tighten the
bolts.
If end play is not 0change the shim again.
Apply RTV sealant to the sealing surface of the
retainer.
Apply sealer to the 4 retainer bolts and tighten
them.

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.

SSANGYONG MY2002
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 MY2002
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 MY2002
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.
Assembly Procedure
1. Install the O-ring and steel ring to the rear of the
extension housing.
2. Install the vent to the extension housing.

MANUAL TRANSMISSION 5B-41
SSANGYONG MY2002
YAD5B0N0
YAD5B0Q0
SHIFT COVER
Disassembly Procedure
1. Using a hammer and a pin punch (3/16) remove
the selector arm roll pin.
2. Before removal, note the correct position of the
interlock plate and selector arm and remove the
shift shaft.
3. Check and clean all removed parts and replace if
necessary.
YAD5B0P0
Assembly Procedure
1. If the shaft cup plug was removed, apply plug
outer surface with sealer and install it into the
cover.
2. Install the fork pads and selector plates onto the
1-2 and 3-4 shift forks.
3. Assemble the sift cover parts as follows :
Push the shift shaft into the cover until the front
of the shaft is at the inside of the cover.
Install the 1-2 shift fork and its selector plate.
YAD5B0R0

SSANGYONG MY2002
5B-42 MANUAL TRANSMISSION
Install the 3-4 shift fork and its selector plate.
YAD5B0V0
YAD5B0S0
YAD5B0U0
YAD5B0T0
Push the shift shaft through the 1-2 shift fork.
Place the selector arm and interlock plate in the
cover.
Note the position of the interlock plate and
selector arm.
Push the shift shaft through the 3-4 shift fork.