1997 SSANGYONG KORANDO lock

SSANGYONG MY2002
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

SSANGYONG MY2002
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

MANUAL TRANSMISSION 5B-5
SSANGYONG MY2002
Check worn or damaged synchronizer
parts and replace if necessary.
Check worn or damaged gears and
replace if necessary.
Add or drain and replace with proper oil.
Tighten as specified.
Realign correctly.
Check bearings, bearing rollers and parts
for wear or damage. Replace if neces-
sary.
Check for worn or damaged
gears(including speedometer gear).
Replace if necessary.
Clean all exposed surfaces, then check
for leaks.
Clean or replace vent or breather.
Check oil level.
Tighten as specified.
Clean leaking surfaces. Reapply sealant.
Replace oil seal.
Action
Worn or damaged synchronizer.
Worn or damaged gears.
Improper or low transmission oil.
Loose bolts or other attaching parts.
Improper flywheel housing to engine
crankshaft alignment.
Noisy transmission bearing.
Noisy gears.
Leakage from transmission.
Vent or breather clogged.
Too much oil.
Loose bolts at sealing faces.
Improperly applied sealant.
Worn or damaged oil seal.Check Applicatio
Transmission locked in
one gear
Transmission noise
Transmission leakage

SSANGYONG MY2002
5B-6 MANUAL TRANSMISSION
DIAGNOSIS TABLE
Transmission Case
Extension Housing
Shift Cover / Shift Shaft
Shift Control Lever
Input Bearing Retainer
Input Gear Set
3rd Speed Gear Set
2nd Speed Gear Set
Reverse Speed Gear Set
1st Speed Gear Set
5th Speed Gear Set
Clutch Housing and Release Derive
Crankshaft Pilot Bushing and Release Bearing
Input Bearing
Main Shaft Input Bearing
Main Shaft Thrust Bearing
3rd Speed Gear Bearing
2nd Speed Gear Bearing
1st Speed Gear Bearing
Reverse Idler Gear Bushing
Counter Shaft Front Bearing
Counter Shaft Rear Bearing
Counter Shaft Thrust Bearing
5th Speed Drive Gear Bearing
Slip Yoke Bushing
Slip Yoke Seal
Speedometer Drive / Driven Gears
Speedometer Driven Gear Housing
Input Shaft Seal
1 - 2 Synchronizer Assembly
3 - 4 Synchronizer Assembly
5th Synchronizer Assembly Applicatio
1 Shift Hop-out
2 Shift Gear Crash
3 Shift Block-out
4 Hard Shift
5 Noise in Reverse Gear
6 Noise in 5th Gear
7 Noise in 4th Gear
8 Noise in 3rd Gear
9 Noise in 2nd Gear
10 Noise in 1st Gear
11 Noise in All Speeds
12 Leak at Transmission Rear Part
13 Leak at Transmission Center Part
14 Leak at Transmission Front
Possible Faulty Part

SSANGYONG MY2002
5B-12 MANUAL TRANSMISSION
1 Remote Shift
2 Shift Lever
3 Shift Inner Boot
4 Lining Shift Socket
5 Control Housing Arm Insulator
6 Control Housing Arm
7 Bushing
8 Shift Rod Link
9 Washer
10 Clip
11 Shift Rod Pin
12 Cover Assembly
13 Shift Tower Cover
14 Bolt
15 Bleeder Hose Barb
16 Control Shift Spring
17 Offset Control Lever
18 Retainer Ring
19 Pin
20 Shift Rail
21 Groove Pin
22 Pin and Clip
23 Joint Assembly
24 Joint Housing
25 Bushing
26 Bolt
27 Bolt
28 O-ring
29 Shaft Rail
30 Case Cover
31 Cap Plug
32 Insert
33 Selecter Plate
34 Selecter Arm
35 Inlockter Plate
36 Selecter Arm Pin
37 Selecter Plate
38 Insert
39 Shift Fork
40 Output Shaft
41 Retainer Ring
42 Washer
43 Inner Corn
44 Outer-Race
45 1-2nd Blocking-Ring
46 Output Shaft Assembly
47 Insert
48 Ball
49 Spring
50 Reverse Sliding Gear
51 1-2nd Blocking-Ring
52 Outer Corn Race
53 Inner Corn
54 Sleeve Bearing
55 Sleeve
56 Needle Bearing
57 1st Speed Driven Gear58 Bearing Corn
59 Bearing Cup
60 Thrust Bearing
61 Thrust Race
62 Blocking-Ring
63 Spring
64 Insert
65 Synchronizer Sleeve
66 Spring
67 Blocking-Ring
68 Synchronizer
69 3rd Speed Gear
70 Needle Bearing
71 Spacer
72 Snap Ring
73 Washer
74 2nd Speed Gear
75 Needle Bearing
76 Spacer
77 Synchronizer Sleeve
78 Bearing
79 O-Ring
80 Bearing
81 Corn Bearing
82 Shaft Gear
83 Counter Shaft Gear
84 Corn Bearing
85 Roll Pin
86 Shift 5th Fork
87 Insert
88 Shift Rail
89 Reverse Fork
90 Spring
91 Retainer Ring
92 Shift Lever
93 5th Speed Driven Gear
94 Snap Ring
95 Bearing Cap
96 Shim
97 Rear Retainer
98 Bolt
99 5th Speed Driven Gear
100 Blocking 5th-Ring
101 Hub Bearing
102 Insert
103 Sleeve
104 Spring
105 Spring
106 Synchronizer
107 5th Synchronizer Retainer
108 Snap Ring
109 Oil Ring Funnel
110 Roll Pin
111 Reverse Idler Shaft
112 Reverse Idler Gear
113 O-Ring
114 Cross member Mounting Hole

SSANGYONG MY2002
5B-28 MANUAL TRANSMISSION
22. Remove the input shaft from the case by rotating
it until the flat surface appears.
23. Remove the following parts from the input shaft.
4th speed gear blocking ring.
Main shaft thrust race and bearing.
Main shaft pilot bearing rollers (15 rollers).
Notice: Be careful not to dissipate the pilot
bearing rollers.
YAD5B630
YAD5B640
YAD5B660
YAD5B650
24. Remove the main shaft in 2 steps.
To remove the rear bearing outer race, push the
main shaft rearward.
Tilt and lift the main shaft from the case.
25. Remove the reverse fork and spring from the case.

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.

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)