Page 1337 of 2053
MANUAL TRANSMISSION 5B-29
SSANGYONG MY2002
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.
Page 1338 of 2053
SSANGYONG MY2002
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 Nm (15 lb-ft)
Page 1339 of 2053
MANUAL TRANSMISSION 5B-31
SSANGYONG MY2002
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 Nm (15 lb-ft)
Tightening Torque 20 Nm (15 lb-ft)
Page 1340 of 2053

SSANGYONG MY2002
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 Nm (21 lb-ft)
Tightening Torque 15 Nm (11 lb-ft)
Page 1341 of 2053

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.
Page 1342 of 2053
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.
Page 1343 of 2053
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.
Page 1344 of 2053
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.