2003 SSANGYONG MUSSO Service Manual

5B-28 MANUAL TRANSMISSION
7. Using a screwdriver, remove the spiral retaining ring.
8. Remove the thrust washer and three-piece 2nd speedblocking 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.
11. Using a hydraulic press and puller plate, remove the 5th speed driven gear from the main shaft.

MANUAL TRANSMISSION 5B-29
12. Remove the main shaft rear bearing assembly from theshaft.
13. Remove the 1st speed gear and bearing.
14. Remove the inner race.
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.

5B-30 MANUAL TRANSMISSION
Assembly Procedure
1. When assemble the synchronizer, make sure that the hubsand 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 Dexron II/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.
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.
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.

MANUAL TRANSMISSION 5B-31
6. Using a hydraulic press and installer, install the 3-4synchronizer hub onto the main shaft. NoticeAlign the blocking ring with the synchronizer keys while installing the hub.

5B-32 MANUAL TRANSMISSION
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.
3. Remove the input bearing.
4. Remove the input shaft seal.
5. Check and clean all removed parts and replace if necessary.

MANUAL TRANSMISSION 5B-33
Assembly Procedure
1. Using a hydraulic press and installer, press the input shaftbearing 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.
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.

5B-34 MANUAL TRANSMISSION
COUNTER SHAFT Disassembly Procedure
1. Using a hydraulic press and special tool, remove the frontbearing assembly from the counter shaft.
2. Check and clean all removed parts and replace if necessary. Assembly Procedure
1. Using a hydraulic press and installer, press the front bearing assembly onto the counter shaft.
2. Install is as follows : Install a new O-ring on the counter shaft outer race and
lubricate it.
Using a installer, lightly tap the race into its bore until the
O-ring is compressed.
Install the race to be fully seated on the inside of the
case.

MANUAL TRANSMISSION 5B-35
EXTENSION HOUSING Disassembly Procedure
1. Remove the vent from the extension housing.
2. Remove the O-ring and steel ring from the rear of theextension housing.
3. Check and clean all removed parts and replace if necessary. Assembly Procedure
1. Install the O-ring and steel ring to the rear of the extension housing.
2. Install the vent to the extension housing.