SsangYong Rexton. Service manual - part 568

MANUAL TRANSMISSION  5B-29

SSANGYONG  Y200

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  Y200

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 N•m (15 lb-ft)

MANUAL TRANSMISSION  5B-31

SSANGYONG  Y200

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 N•m (15 lb-ft)

Tightening Torque

20 N•m (15 lb-ft)

SSANGYONG  Y200

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 N•m (21 lb-ft)

Tightening Torque

15 N•m (11 lb-ft)