1997 SSANGYONG KORANDO lock

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.

MANUAL TRANSMISSION 5B-37
SSANGYONG MY2002
YAD5B960
YAD5B970
YAD5B990
15. Remove the tree-piece 1st speed blocking ring
assembly and remaining synchronizer spring.
16. Check and clean all removed parts and replace if
necessary.
Assembly Procedure
1. When assemble the synchronizer, make sure that
the hubs and sleeves are matched and the 3 keys
are installed properly. Also align blocking rings
with keys during installation.
Notice: Before assembly, coat all parts with
lubricant. In case of the paper-lined blocking rings,
soak them in DexronII/III before installation.
2. Assemble the following parts :
1st speed blocking ring.
Alignment pin and 1st speed gear bearing race.
1st speed gear and its bearing.
3. Install the rear bearing assembly to the main shaft.
YAD5B980
4. Using a hydraulic press and installer, press the
5th driven gear onto the main shaft. While the
main shaft is still on the press bed, install the 5th
driven gear snap ring. If the snap ring does not fit
completely, continue pressing the 5th driven gear.

SSANGYONG MY2002
5B-38 MANUAL TRANSMISSION
5. Install the following parts :
2nd speed blocking ring assembly.
Thrust washer for the blocking ring inner cone.
Spiral retaining ring (Use special tools).
2nd speed gear spacer, bearing and gear.
2nd gear thrust washer and snap ring.
3rd speed gear spacer, bearing and gear.
3rd speed blocking ring.
YAD5B0A0
YAD5B0B0
YAD5B0D0
YAD5B0C0
6. Using a hydraulic press and installer, install the
3-4 synchronizer hub onto the main shaft.
Notice: Align the blocking ring with the
synchronizer keys while installing the hub.
INPUT SHAFT
Disassembly Procedure
1. Remove the following parts from the input shaft :
Main shaft thrust race and bearing.
Main shaft pilot bearing rollers (15 rollers).
2. Using a hydraulic press and puller plate, remove
the input shaft bearing assembly from the shaft.

MANUAL TRANSMISSION 5B-41
SSANGYONG MY2002
YAD5B0N0
YAD5B0Q0
SHIFT COVER
Disassembly Procedure
1. Using a hammer and a pin punch (3/16) remove
the selector arm roll pin.
2. Before removal, note the correct position of the
interlock plate and selector arm and remove the
shift shaft.
3. Check and clean all removed parts and replace if
necessary.
YAD5B0P0
Assembly Procedure
1. If the shaft cup plug was removed, apply plug
outer surface with sealer and install it into the
cover.
2. Install the fork pads and selector plates onto the
1-2 and 3-4 shift forks.
3. Assemble the sift cover parts as follows :
Push the shift shaft into the cover until the front
of the shaft is at the inside of the cover.
Install the 1-2 shift fork and its selector plate.
YAD5B0R0

SSANGYONG MY2002
5B-42 MANUAL TRANSMISSION
Install the 3-4 shift fork and its selector plate.
YAD5B0V0
YAD5B0S0
YAD5B0U0
YAD5B0T0
Push the shift shaft through the 1-2 shift fork.
Place the selector arm and interlock plate in the
cover.
Note the position of the interlock plate and
selector arm.
Push the shift shaft through the 3-4 shift fork.

SSANGYONG MY2002
5B-46 MANUAL TRANSMISSION
8. Check the following Bearing for excessive war:
Crankshaft pilot bushing for the front of the input
shaft.
Clutch release bearing.
Input shaft bearing.
Main shaft pilot bearing rollers.
Main shaft thrust Bearing and its surfaces.
YAD5B1J0
YAD5B1F0
YAD5B1H0
YAD5B1G0
6. Check worn edges on the following parts :
Selector arm.
Interlock plate.
Selector plates for the 1-2 and 3-4 shift forks.
5-R shift lever and the rollers on the reverse
fork and the 5th shift rail/fork.
7. Check worn mating surfaces on the following parts :
1-2 shift fork, pads and synchronizer sleeve.
3-4 shift fork, pads and synchronizer sleeve.
5th shift rail/fork pads and synchronizer sleeve.
Reverse fork and reverse idler gear sleeve.

SSANGYONG MY2002
5B-48 MANUAL TRANSMISSION
14. Check for gear clash on the synchronizer sleeve
teeth or the clutch teeth on the speed gear.
15. Check the synchronizer sleeve and gear clutch
tooth for hop-out.
YAD5B1S0
YAD5B1P0
YAD5B1R0
YAD5B1Q0
The 5th blocking ring.
12. Check the fit between the hub and sleeve of each
synchronizer
Excessively tight or loose hub-to-sleeve fit.
Wear of the cone clutch surfaces of brass
blocking rings and gears.
13. Measure the clearance between the blocking ring
and the speed gear
New 1-2 blocking ring : 0.87 - 1.4mm
New 3-4 blocking ring : 0.88 - 1.5mm
Notice: Excessive wear of the blocking ring or the
speed gear cone surface will cause shift block-
out gear clash.

Specifications.......................................................5C-2
General Specifications.........................................5C-2
Fastener Tightening Specifications.......................5C-2
Component Locator.............................................5C-3
Clutch Assembly.................................................5C-3
Pedal and Master Cylinder...................................5C-4
Maintenance and Repair.....................................5C-5
On-Vehicle Service.................................................5C-5
Bleeding of Clutch System...................................5C-5
Clutch Disc......................................................... 5C- 6
Master Cylinder.................................................5C-10Clutch Pedal...................................................... 5C-12
Clutch Oil Chamber........................................... 5C-14
Diagnosis............................................................ 5C-15
Clutch Slips....................................................... 5C-15
Poor Disengagement ......................................... 5C-15
Hard to Shift or Will not Shift............................... 5C-15
Clutch Chatters When Starting........................... 5C-15
Difficult Pedal Operation.................................... 5C-16
Clutch Noisy...................................................... 5C-16
Special Tools and Equipment............................ 5C-17
Special Tools Table............................................ 5C-17
SECTION 5C
CLUTCH
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.
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