1997 SSANGYONG KORANDO transmission

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)

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.

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.

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.

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.

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-39
SSANGYONG MY2002
YAD5B0E0
YAD5B0F0
YAD5B0H0
3. Remove the input bearing.
4. Remove the input shaft seal.
5. Check and clean all removed parts and replace if
necessary.
Assembly Procedure
1. Using a hydraulic press and installer, press the
input shaft bearing onto the input shaft.
2. Apply grease to the thrust bearing inner roller (15
rollers) and install the main shaft thrust bearing
and its race in the rear of the input shaft.
YAD5B0G0
3. Using a rubber hammer and installer, install the
input bearing retainer and input shaft seal after
applying grease.
4. Install the bearing outer race to the retainer without
end play adjusting shim.