2003 SSANGYONG MUSSO Service Manual

5B-20 MANUAL TRANSMISSION
18. Remove the slip yoke snap ring from the main shaft.
19. Remove the 5th speed drive gear snap ring from the mainshaft.
20. Make alignment marks on the case and input bearing retainer and remove the 4 input shaft bearing retainer bolts, using a 13 mm wrench. Notice
Apply sealer on these bolts during assembly.Remove the input bearing retainer with the bearing outer race and shim.
21. Remove the input shaft from the case by rotating it until the flat surface appears.
22. 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.

MANUAL TRANSMISSION 5B-21
23. 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.
24. Remove the reverse fork and spring from the case.
25. 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.

5B-22 MANUAL TRANSMISSION
26. Using a pin punch and a hammer, remove the roll pin fixedon the reverse idler shaft.
27. By pushing the reverse idler shaft rearward and out of the case, remove the reverse idler gear and O-ring.
28. Using a puller, remove the rear bearing assembly from the counter shaft.

MANUAL TRANSMISSION 5B-23
Assembly Procedure
1. Using a hydraulic press and a supporting tool, press thecounter shaft rear bearing into the case. Be sure that the supporting tool inside of the case should support the counter shaft.
2. Without the shim, install the retainer and counter shaft rear bearing outer race. Tighten the 4 retainer bolts.
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

5B-24 MANUAL TRANSMISSION
7. Install the counter shaft rear bearing outer race, shim andretainer.
Tightening Torque 39 - 52 Nm
Using a punch and hammer, bend the lock tabs on the
retainer.
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.
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.
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.
Tightening Torque 28 Nm
13. Using a needle nose pliers, install the 5-R lever clip.

MANUAL TRANSMISSION 5B-25
14. Using a needle nose pliers, install the reverse fork springto 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.
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.
20. Place the detent spring and offset lever in the extension housing and push the extension against the case and shift
cover.

5B-26 MANUAL TRANSMISSION
21. Completely compress the detent spring.
22. To install the extension housing to the case, apply sealerto 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 thethinner one in first.
Install the retainer to the case and tighten the bolts.
If end play is not ‘0’change the shim again.
Apply RTV sealant to the sealing surface of the retainer.
Apply sealer to the 4 retainer bolts and tighten them.
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.

MANUAL TRANSMISSION 5B-27
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.
6. Remove the 2nd speed gear, bearing and spacer.