SSANGYONG MUSSO 2003 Service Manual

5B-22 MANUAL TRANSMISSION
26. Using a pin punch and a hammer, remove the roll pin fixedon the reverse idler shaft.
27. By pushing the reverse idler shaft rearward and out of the case, remove the reverse idler gear and O-ring.
28. Using a puller, remove the rear bearing assembly from the counter shaft.

MANUAL TRANSMISSION 5B-23
Assembly Procedure
1. Using a hydraulic press and a supporting tool, press thecounter shaft rear bearing into the case. Be sure that the supporting tool inside of the case should support the counter shaft.
2. Without the shim, install the retainer and counter shaft rear bearing outer race. Tighten the 4 retainer bolts.
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

5B-24 MANUAL TRANSMISSION
7. Install the counter shaft rear bearing outer race, shim andretainer.
Tightening Torque 39 - 52 Nm
Using a punch and hammer, bend the lock tabs on the
retainer.
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.
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.
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.
Tightening Torque 28 Nm
13. Using a needle nose pliers, install the 5-R lever clip.

MANUAL TRANSMISSION 5B-25
14. Using a needle nose pliers, install the reverse fork springto 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.
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.
20. Place the detent spring and offset lever in the extension housing and push the extension against the case and shift
cover.

5B-26 MANUAL TRANSMISSION
21. Completely compress the detent spring.
22. To install the extension housing to the case, apply sealerto 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 thethinner one in first.
Install the retainer to the case and tighten the bolts.
If end play is not ‘0’change the shim again.
Apply RTV sealant to the sealing surface of the retainer.
Apply sealer to the 4 retainer bolts and tighten them.
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.

MANUAL TRANSMISSION 5B-27
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.
6. Remove the 2nd speed gear, bearing and spacer.

5B-28 MANUAL TRANSMISSION
7. Using a screwdriver, remove the spiral retaining ring.
8. Remove the thrust washer and three-piece 2nd speedblocking 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.
11. Using a hydraulic press and puller plate, remove the 5th speed driven gear from the main shaft.

MANUAL TRANSMISSION 5B-29
12. Remove the main shaft rear bearing assembly from theshaft.
13. Remove the 1st speed gear and bearing.
14. Remove the inner race.
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.

5B-30 MANUAL TRANSMISSION
Assembly Procedure
1. When assemble the synchronizer, make sure that the hubsand 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 Dexron II/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.
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.
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.

MANUAL TRANSMISSION 5B-31
6. Using a hydraulic press and installer, install the 3-4synchronizer hub onto the main shaft. NoticeAlign the blocking ring with the synchronizer keys while installing the hub.