SsangYong Rexton. Service manual - part 561

SECTION 5B

MANUAL TRANSMISSION

TABLE OF CONTENTS

General Description and Operation ..................... 5B-2

Shift Lever ........................................................... 5B-2

Transmission Assembly ....................................... 5B-2

Specifications ...................................................... 5B-3

Diagnostic Information and Procedures .............. 5B-4

Diagnosis Table ................................................... 5B-6

Component  Locator ............................................ 5B-7

Cross-Sectional View ........................................... 5B-7

Power Flow .......................................................... 5B-8

Seni-Remote Kit Disassembly and Assembly ....... 5B-9

Transmission Assembly ..................................... 5B-10

Transmission Assembly Disassembled View ...... 5B-11

Maintenance and Repair ................................... 5B-14

On-Vehicle Service ............................................... 5B-14

Semi-Remote Kit ................................................ 5B-14

Transmission ..................................................... 5B-19

Unit Repair .......................................................... 5B-24

Major Unit .......................................................... 5B-24

Main Shaft ......................................................... 5B-34

Input Shaft ........................................................ 5B-38

Counter Shaft .................................................... 5B-40

Extension Housing ............................................. 5B-40

Shift Cover ........................................................ 5B-41

Inspection of Components ................................. 5B-45

SSANGYONG  Y200

5B-2  MANUAL TRANSMISSION

GENERAL DESCRIPTION AND OPERATION

SHIFT LEVER

The shift lever is a type of linkage connected directly
and lock shifting from 5th to reverse. This unit
decreases the possibility of any blown, wear etc.

YAD5B010

YAD5B020

YAD5B030

TRANSMISSION ASSEMBLY

MANUAL TRANSMISSION  5B-3

SSANGYONG  Y200

Model

Type

Gear Ratio

Oil

Weight (Dry)

1st

2nd

3rd

4th

5th

Reverse

Specification

Capacity(litre)

Change Interval

Application

SPECIFICATIONS

T5WC

Floor Change

3.969 : 1

2.341 : 1

1.457 : 1

1.000 : 1

0.851 :1

3.710 : 1

ATF DEXRON II / III

3.4 L

Check : Every 15,000 km,

Replace : Every 50,000 km

33kg

Description

Notice: Add LUBRIZOL (280cc) in oil after overhauling.

SSANGYONG  Y200

5B-4  MANUAL TRANSMISSION

DIAGNOSTIC INFORMATION AND PROCEDURES

Control lever assembly broken or dam-

aged.

Damaged offset lever, shift fork, selector

place or selector arm.

Clutch not releasing.

Improper or low transmission oil.

Shift or shift rail binding.

Binding of sliding synchronizers or gears.

If reverse only, faulty backup switch.

Worn or damaged flywheel pilot bushing.

Engine idle speed too high.

Damaged or faulty clutch.

Pilot bearing between input shaft and

output shaft binding.

Damaged synchronizer.

Bell housing misaligned.

Damaged gear(s).

Worn or damaged flywheel pilot bushing.

Loosened transmission or flywheel

housing bolts, improper alignment.

Synchronizer damaged or excessively

worn.

Blocking ring damaged, worn index slots

or friction surfaces worn or damaged.

Excessive countershaft end play.

Worn or damaged fork due to loosened

shaft, rail or shifting fork.

Fork or offset lever loose on shaft or rail.

Worn or damaged forks, offset lever,

shaft or rail.

Replace control lever and housing assem-

bly.

Remove extension, adapter or case

cover. Check or replace damaged parts.

Adjust or replace clutch.

Add or replace with specified oil.

Remove extension, adapter or case

cover. Check or replace damaged parts.

Remove extension, adapter or case

cover. Check synchronizers and gears

and replace damaged parts.

Check or replace backup switch.

Replace pilot bushing.

Adjust idle speed to specified speed.

Adjust or replace clutch.

Replace or check roller bearings.

Check or replace synchronizer parts.

Align bell housing and bore.

Check or replace gear(s).

Replace pilot bushing.

Tighten bolts to specified value. Realign

if necessary.

Check or replace synchronizer parts.

Check or replace blocking ring.

Check worn or damaged parts. Adjust

shim thickness using roller bearings if

necessary.

Check for wear or damaged. Replace

worn or damaged parts.

Replace extension, adapter or case

cover. Check or replace loose parts on

shaft or rail. Replace roll pin(s).

Remove extension, adapter or case

cover. Check for wear or damaged.

Replace damaged parts.

Check

Applicatio

Will not shift

(control lever moves)

Hard shift or control

lever will not move into

gear

Gears crash when

shifting

Transmission jumps

out

Transmission locked in

one gear

Action