SSANGYONG MUSSO 1998 Workshop Repair Manual

5A-124 AUTOMATIC TRANSMISSION
27. Install the line pressure plug and tighten to specification.
Refer to figure 8.62.
28. Install the detent spring assembly (spring, support plate
and screw), ensuring that the screw is tightened to
specification. Check the spring for wear or damage.
29. Install the manual shift valve. Refer to figure 8.60.
Notice
Be aware that the manual valve will fall out of the valve
body.
Figure 8.62 - Wiring Installation
Figure 8.60 - Manual Shift Valve

AUTOMATIC TRANSMISSION 5A-125
30. Align the valve body assembly on the transmission case
and install the manual valve lever to manual valve link. Fit
the long end of the link to the manual valve first. Install the
securing bolts and tighten to specification in the specified
sequence. Refer to figure 8.61.
31. Check the alignment of the detent roller and the manual
lever quadrant.
32. Connect the solenoid wiring as detailed below:
lSolenoid 1 - red
lSolenoid 2 - bIue
lSolenoid 3 - yellow
lSolenoid 4 - orange
lSolenoid 5 - green
lSolenoid 6 - violet (Refer to figure 8.62.)
Notice
All hardware must be correctly installed and torqued to
specification.
Figure 8.61 - Tightening Sequence Valve Body to Case

5A-126 AUTOMATIC TRANSMISSION
Oil Filter and Pan Assembly
Notice
1. Replace the filter whenever rebuilding a transmission where a significant amount of mechanical damage has
occurred.
2. To aid the assembly of the pan gasket, use a small amount of Vaseline at the pan/gasket interface. This ensures
that the gasket remains on the pan ridge. Do not over torque pan bolts as this may distort the pan and cause
leaks.
3. Ensure that the internal line pressure plus in the valve body is fitted.
To assemble the oil filter and pan assembly (refer to figures 8.63 and 8.64), proceed as follows.
1. Lubricate the oil filter sealing ring with automatic transmission fluid.
2. Carefully assemble the oil filter to the valve body. The spigot must not lean on one side while being fitted. Refer to
figure 8.63.
3. Secure the oil falter assembly with the retainer.
4. Check that the magnet is located in the dimple in the comer of the oil pan.
5. Assemble the gasket on the pan lip. The gasket must be free of any distortion when installed.
6. Fit the oil pan assembly to the transmission case and tighten the securing bolts to specification and sequence
(refer to figure 8.65). Do not over torque.

AUTOMATIC TRANSMISSION 5A-127
Torque Converter and Housing Assembly
To assemble the torque converter and housing assembly,
proceed as follows.
1. Locate the torque converter housing on the transmission
main case.
2. Install and tighten the securing bolts to specification.
Notice
All the hardware must be correctly installed and torqued to
specification.
3. Fit the converter ensuring that the tangs are engaged in
the pump gear. Ensure that the tangs do not contact the
pump seal.
Figure 8.1 - Torque Specifications
Torque Specifications
Torque converter housing to case
Extension housing to case
Rear servo cover
Pan to case
Inhibitor switch to case
Cooler connectors
Transmission filler plug
Output flange lock nut (RWD models)
Centre support to case
Cam plate to case (parking pawl)
Valve body to case
Upper valve body to lower valve body
ON/OFF solenoid retainers
Variable pressure solenoid retainer
Line pressure plug
Detent spring
Pump cover to case
Pump cover plate to pump cover
Pump to pump adaptor
Pump cover plate to crescent
Adaptor to caseNlm
54 - 68
54 - 68
25 - 35
4 - 6
2.3 - 3.4
30 - 35
30 - 35
100 - 110
20 - 27
16 - 22
8 - 13
11 - 16
8 - 12
8 - 12
4 - 7
20 - 22
24 - 34
13 - 16
24 - 27
13 - 16
25 - 35

5A-128 AUTOMATIC TRANSMISSION
FRONT AND REAR BAND ADJUSTMENT
Front Band Setting Procedure
To set the front band, proceed as follows.
1. Measure the projection of the front servo push rod from the transmission case. Refer to figure 8.66, dimension A.
a. Apply air at 650/700 kPa to the front servo apply area (B1 outer). (Refer to figure 8.67.)
b. Measure the travel of the push rod and subtract 3 mm to find the shim size required.
c. Release the air.
Notice
A minimum of one shim is required at all times - minimum shim size is 1 mm. The thicknesses of available shims
are listed in table 8.2.
2. Fit the selected shim(s) to the shank of the anchor strut as follows:
a. Inspect the shim(s) for damage, wear or corrosion. Replace as necessary.
b. The shim(s) are to be installed between the case abutment face and the anchor strut flange. Refer to figure
8.66.
c. The shim(s) are to be fitted by hand and under no circumstances to be hammered or forced.
d. Shim(s) are to be pressed on by hand until an audible click is heard. The click indicates that the shim is clipped
home correctly.
3. Re-check that the push rod travel is 3 mm ± 0.25 mm.
Figure 8.66 - Front Band Settings

AUTOMATIC TRANSMISSION 5A-129
Figure 8.68 - Rear Band Settings
Rear Band Setting Procedure
To set the rear band, proceed as follows.
1. Measure distance ‘A’ from the rear servo piston to the inner face of the transmission case using vernier calipers.
Refer to figure 8.68.
a. Apply air at 650/700 kPa to the rear servo apply area (B2 outer). Refer to figure 8.67.
b. Measure the travel of the piston, subtract 3.75 mm and divide the remainder by 2.5 to find shim size.
c. Release the air.
Notice
A minimum of one shim is required at all times - minimum shim size is 1 mm. The thickness of available shims
are listed in table 8.2.
2. Fit the selected shim(s) to the shank of the anchor strut as follows.
a. Inspect the shim(s) for damage, wear or corrosion and replace as necessary. The shim(s) are to be installed
between the case abutment face and the anchor strut flange. Refer to figure 8.68.
c. The shim(s) are to be fitted by hand and under no circumstances to be hammered or forced.
d. The shim(5) are to be pressed on by hand until an audible click is heard. The click indicates that the shim is
clipped home correctly.
3. Re-check that the piston travel is 3.75 mm ± 0.625 mm.

5A-130 AUTOMATIC TRANSMISSION
Table 8.2 - Thickness of Available Shims
Thickness
0.95/1.05
1.15/1.25
1.44/1.56
1.73/1.87Part Number
0574-037017
0574-037018
0574-037019
0574-037020Thickness
1.93/2.07
2.12/2.28
2.42/2.58
2.61/2.79Part Number
0574-037021
0574-037022
0574-037023
0574-037024
Figure 8.68 - Thickness of Available Shims

Model
Type
Gear Ratio
Oil
Weight (Dry)
SECTION 5B
MANUAL TRANSMISSION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5B-1
General Specifications . . . . . . . . . . . . . . . . . . 5B-1
Fastener Tightening Specifications . . . . . . . . . 5B-2
External View . . . . . . . . . . . . . . . . . . . . . . . . 5B-3
Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-3
Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5
Will not Shift (Control Lever Moves) . . . . . . . . 5B-5
Hard Shift or Control Lever Will not Move Into
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5
Gears Crash When Shifting . . . . . . . . . . . . . . 5B-5
Transmission Jumps Out . . . . . . . . . . . . . . . . . 5B-6
Transmission Locked in One Gear . . . . . . . . . 5B-6
Transmission Noise . . . . . . . . . . . . . . . . . . . . . 5B-6
Transmission Leakage . . . . . . . . . . . . . . . . . . 5B-7Diagnosis Table . . . . . . . . . . . . . . . . . . . . . . . 5B-8
Component Locator . . . . . . . . . . . . . . . . . . . 5B-9
Maintenance and Repair . . . . . . . . . . . . . . 5B-11
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 5B-11
Shift Control Cable . . . . . . . . . . . . . . . . . . . . 5B-11
Transmission . . . . . . . . . . . . . . . . . . . . . . . . 5B-14
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17
Major Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17
Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-27
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-32
Counter Shaft . . . . . . . . . . . . . . . . . . . . . . . . 5B-34
Extension Housing . . . . . . . . . . . . . . . . . . . . 5B-35
Shift Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-36
Inspection of Components . . . . . . . . . . . . . . 5B-40
Pre-Installation Checks . . . . . . . . . . . . . . . . . 5B-45
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Description
T5WC
Floor Change
3.97 : 1
2.34 : 1
1.46 : 1
1.00 : 1
0.85 :1
3.71 : 1
ATF DEXRON II / III
3.4 L
Check : Every 15,000km, Replace : Every 50,000km
33kg 1st
2nd
3rd
4th
5th
Reverse
Specification
Capacity(litre)
Change Interval
Notice
Add LUBRIZOL (280cc) in oil after overhauling.

5B-2 MANUAL TRANSMISSION
FASTENER TIGHTENING SPECIFICATIONS
Application
Transmission
Oil Filler Plug
Transmission Mounting Bolt (Housing)
Oil Drain Plug
Front Propeller Shaft (T/C)
Rear Propeller Shaft (T/C)
Cross Member Bolt (Center)
Cross Member Bolt (Side)
Control Cable
Shift Lever BoltNlm
25
77 - 87
25
81 - 89
70 - 90
21 - 35
62 - 93
20 - 30

MANUAL TRANSMISSION 5B-3
EXTERNAL VIEW
GEAR TRAIN