1997 SSANGYONG KORANDO manual transmission

SSANGYONG MY2002
5B-18 MANUAL TRANSMISSION
8. Insert the washer and assemble the snap ring.
YAD5B130
YAD5B260
9. Insert the control housing arm insulator to the semi-
remote kit.
YAD5B250
7. Assemble the shift rod, the shift rail and U-joint
using the pin.

MANUAL TRANSMISSION 5B-19
SSANGYONG MY2002
TRANSMISSION
Removal Procedure
1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the drain plug from the transmission
housing and drain the oil. Reinstall the drain plug.
4. Disconnect the back-up switch connector.
5. Remove the breather hose.
YAD5B280
YAD5B290
YAD5B300
YAD5B310
6. Remove the speedometer connector and other
wiring harnesses and connectors.

SSANGYONG MY2002
5B-20 MANUAL TRANSMISSION
7. Remove the front and rear propeller shafts from
the transfercase.
8. Support the transmission on an suitable jack.
Unscrew the center mounting nuts and each sides
mounting bolts and remove the cross member.
9. Remove the transmission mounting bolts.
Notice: For removing the transmission, there may
be any damage in the clutch housing inside CSC.
Thus remove the transmission with the clutch
housing.
10. Move the transmission jack backward careful and
disengage the transmission input shaft from the
engine.
Remove the transmission.
YAD5B320
YAD5B330
YAD5B340
YAD5B020

MANUAL TRANSMISSION 5B-21
SSANGYONG MY2002
Pre-Installation Checks Checking Procedure
1. Separate the clutch release fork from the pivot and
remove the pivot from the clutch housing.
2. Check the pivot. Fork and release bearing.
3. Check the pressure plate spring.
Notice: Inspect each parts and replace the
excessively worn parts.
4. Check the clutch housing alignment as follows :
Place the magnetic base on the pressure plate
spring.
Check the housing bore alignment.
YAD5B350
YAD5B360
YAD5B370
YAD5B380
- Place the dial indicator on the bore.
- By rotating the crankshaft one revolution,
record the dial indicator reading.

SSANGYONG MY2002
5B-22 MANUAL TRANSMISSION
62 - 93 Nm
(45 - 69 lb-ft)
21 - 35 Nm
(15 - 26 lb-ft)
Check the housing face alignment.
- Place the dial indicator on the housing face.
- By rotating the crankshaft one revolution,
record the dial indicator reading.
Notice: If the reading is greater than 0.010 inch,
insert the shim between the engine and clutch
housing and adjust the alignment.
5. Check the following parts :
Pressure plate spring assembly
Disc
Flywheel
Input shaft pilot bearing
Notice: Replace the excessively worn parts.
6. Lubricate the clutch release bearing bore, fork
pivot head during assembly.
Installation Procedure
1. Install the transmission to the vehicle. At this time,
seat correctly the input shaft of the transmission
on the pilot bearing of the flywheel.
2. Tighten the transmission mounting bolts as the
specified torque on the vehicle.
Installation Notice
YAD5B390
YAD5B400
YAD5B410
YAD5B420
Tightening Torque77 - 87 Nm
(57 - 64 lb-ft)
3. Install the cross member and tighten as the
specified torque by supporting the suitable jack.
Installation Notice
Tightening
TorqueLeft/Right
Center

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.