clutch SSANGYONG MUSSO 2003 Workshop Manual

5A-44 AUTOMATIC TRANSMISSION CLUTCH PACKS
There are four clutch packs (refer to figure 4.3). All clutch packs are composed of multiple steel and friction plates. C1 CLUTCHWhen applied, this clutch pack allows the input shaft to drive the planet carrier.
This occurs in third and fourth gears.C2 CLUTCH When applied this clutch pack allows the input shaft to drive the forward sun gear via the 3-4 OWC.
This occurs in all forward gears.C3 CLUTCH When applied this clutch pack allows the input shaft to drive the reverse sun gear. This only occurs in
reverse gear.C4 CLUTCH When applied this clutch provides engine braking on overrun. This occurs in Manual 1, 2 and 3 and
also Drive 2 and Drive 3 to prevent objectionable free wheel coasting.
Figure 4.3 - Clutch Packs

AUTOMATIC TRANSMISSION 5A-45
BANDS
The transmission utilises two bands, the B1 band (sometimes known as the 24 band), and the B2 band (sometimes
known as the low-reverse band). Refer to figure 4.4.
The B1 band is a flexible band which is engaged by the front servo piston. B1 is activated in second and fourth gear.
When activated B1 prevents the reverse sun gear from rotating by holding the C3 clutch assembly stationary. In
second gear only the outer area of the apply piston is utilised. In fourth gear both areas are utilised for greater clamping force.
The B2 band is a solid band which is engaged by the rear servo piston. B2 is activated in Park,
Reverse, Neutral and Manual 1. When activated B2 prevents the planet carrier assembly from rotating. In Manual 1
only the inner area of the apply piston is utilised. In Park, Reverse and Neutral, both areas are utilised for greater clamping force. Figure 4.4- Bands
ONE WAY CLUTCHES
The transmission uses two OWCs, the 1-2 OWC and the 34 OWC. (Note that a third OWC is located in the torque
converter, also known as a sprag.)
The 1-2 OWC is located between the planetary carrier assembly and the centre support. This allows the carrier to
rotate around the centre support in one direction only. The one way clutch is engaged only in Drive 1.
The 3-4 OWC is located between the C4 and the C2 clutch assemblies. This allows the C2 clutch to drive the forward
sun gear in first, second and third gears but unlocks in fourth gear and during overrun.
PLANETARY GEAR SET
The planetary gear set used in the transmission is a conventional six pinion Ravigneaux compound gear set.

AUTOMATIC TRANSMISSION 5A-47
POWER FLOWS
INTRODUCTION
The power flows for the various transmission selections are listed below: Power Flow - Neutral and Park
Power Flow - Reverse
Power Flow - Manual 1
Power Flow - Drive 1
Power Flow - Drive 2
Power Flow - Drive 3
Power Flow - Drive 3 Lock Up
Power Flow - Drive 4 (Overdrive)
Power Flow - Drive4 Lock Up
Each power flow is described in the following sections.
Table 5.1 details the engaged elements versus the gear selected for all transmission selections.
Gear State
Park and Neutral Reverse Manual 1 Drive 1Drive 2 and Manual 2Drive 3 and Manual 3Drive 3 Lock Up and Manual 3 Lock Up Drive 4 OverdriveDrive 4 Lock Up C1
-- - --
XX X X C2
--
XXXX X X X C3
-
X - - -- - - - C4
--
X
-
XXX
-- B1
-- - -
X
- - - - B2
XXX- - -- - - 1-2
OWC - --
X
--- - - 3-4
OWC - -
XX X XX
- - LU
CLUTCH - --- - -
X
-
X
ELEMENTS ENGAGED
Figure 5.1 - Engaged Elements vs Gear Selected
Planetary Gear Set

5A-48 AUTOMATIC TRANSMISSION POWER FLOW - PARK AND NEUTRAL
In Park and Neutral, there is no drive to the planetary gear set. The rear band is applied to eliminate ‘clunk’ on
engagement of the reverse gear, and to improve the low range engagement for 4WD applications. No other clutches
or bands are applied.
In Park the transmission is mechanically locked by engaging a case mounted pawl with teeth on the output shaft ring
gear. Control
To maintain this arrangement in the steady state solenoids and valves are activated as follows:
Solenoids S1 and S2 are switched off.
Line (pump) pressure is applied to the primary regulator valve (PRV) and to the solenoid supply valve.
The converter, oil cooler, and lubrication circuits are charged from the primary regulator valve.
The line 500 circuit is charged by the solenoid supply valve.
The S5 circuit is charged by the variable pressure solenoid (S5).
Line pressure is prevented from entering the drive circuit by the manual valve.
The B1 circuit and all clutch circuits are open to exhaust.
Refer to figure 5.1 and table 5.2.
Table 5.2 - Engaged Elements - Park arid Neutral
Gear State
Park and Neutral C1
- C2
- C3
- C4
- B1
- B2
X 1-2
OWC - 3-4
OWC - LU
CLUTCH -
ELEMENTS ENGAGED

AUTOMATIC TRANSMISSION 5A-49
POWER FLOW - REVERSE
In Reverse, transmission drive is via the input shaft and the forward clutch cylinder to the hub of the C3 clutch. The
elements of the transmission function as follows : The C3 clutch is engaged and drives the reverse sun gear in a clock-wise direction.
The B2 band is engaged and holds the planetary gear carrier stationary causing the long pinion to rotate anti-
clockwise about its axis on the pinion shaft.
The long pinion drives the internal ring fear in the same direction.
The internal ring being splined to the output shaft drives it in an anti-clockwise or reverse direction.
Control
To maintain this arrangement in the steady state solenoids and valves are activated as follows: Solenoids S1 and S2 are switched off.
Line pressure is directed through the reverse lockout valve to both the inner and outer apply areas of the rear
servo piston for B2 band application.
Line pressure feeds the reverse oil circuit via the manual valve.
Reverse oil is routed from the manual valve to the C3 clutch.
Reverse oil is also applied to the spring end of the primary regulator valve to assist the spring and to boost theline pressure value.
All other clutch and band apply circuits are open to exhaust.
Refer to figure 5.2 and table 5.3
Table 5.3 - Engaged Elements - Reverse
Gear State
Reverse C1
- C2
- C3
X C4
- B1
- B2
X 1-2
OWC - 3-4
OWC - LU
CLUTCH -
ELEMENTS ENGAGED

5A-50 AUTOMATIC TRANSMISSION POWER FLOW - MANUAL 1 In Manual 1, transmission drive is via the input shaft
to the forward clutch cylinder. The elements of thetransmission function as follows : The C2 clutch is engaged to drive the forward sun gear, via the 3-4 OWC.
The B2 band is engaged to hold the planetary gear carrier stationary.
The forward sun gear drives the short pinion anti-clockwise.
The short pinion drives the long pinion clockwise.
The long pinion rotating about its axis drives the internal ring gear and the output shaft in a clockwise or
forward direction.
The C4 clutch provides engine braking through the 3-4 OWC on overrun.
Control
To maintain this arrangement in the steady state solenoids and valves are activated as follows: Solenoids S1 and S2 are switched ON.
The 1-2,2-3, and 34 shift valves are held in their first gear positions by line 500 pressure.
Drive (line pressure) oil from the manual valve engages the C2 clutch.
Lo-1st (line pressure) oil is routed through the 1-2 shift valve to the C4 clutch, and to the inner apply area of
the rear servo piston for B2 band application.
Refer to figure 5.3 and table 5.4.
Table 5.4 - Engaged Elements - Manual 1
Gear State
Manual 1 C1
- C2
X C3
- C4
X B1
- B2
X 1-2
OWC - 3-4
OWC X LU
CLUTCH -
ELEMENTS ENGAGED

AUTOMATIC TRANSMISSION 5A-51
POWER FLOW - DRIVE 1
In Drive 1, transmission drive is via the input shaft to the forward clutch cylinder. The elements of the transmission function as follows : The C2 clutch is engaged to drive the forward sun gear.
The forward sun gear drives the short pinion anti-clockwise.
The short pinion drives the long pinion clockwise.
The 1-2 OWC prevents the planetary gear carrier from rotating under reaction force and the long pinion
rotates on its axis driving the internal ring gear and output shaft in a clockwise or forward direction.
There is no engine braking on overrun.
Control
To maintain this arrangement in the steady state solenoids and valves are activated as follows: Solenoids S1 and S2 are switched On.
The 1-2, 2-3, and 3-4 shift valves are held in their first gear positions by line 500 pressure.
Drive (line pressure) oil from the manual valve engages the C2 clutch.
Refer to figure 5.4 and table 5.5
Table 5.5 - Engaged Elements - Drive 1
Gear State
Drive 1 C1
- C2
X C3
- C4
- B1
- B2
- 1-2
OWC X 3-4
OWC X LU
CLUTCH -
ELEMENTS ENGAGED

5A-52 AUTOMATIC TRANSMISSION POWER FLOW - DRIVE 2 AND MANUAL 2
In Drive 2 and Manual 2, transmission drive is via the input shaft and forward clutch cylinder. The elements of the
transmission function as follows :
The C2 clutch is applied to drive the forward sun gear.
The forward sun gear drives the short pinion anti-clockwise.
The short pinion drives the long pinion clockwise.
The B1 band is applied holding the reverse sun gear stationary therefore the long pinion ‘walks’ around the
reverse sun gear taking the internal ring gear and output shaft with it in a clockwise or forward direction.
The C4 clutch is applied to bypass the 3-4 OWC and provide engine braking on overrun.
Control
To maintain this arrangement in the steady state solenoids and valves are activated as follows: Solenoid S1 is switched Off. S2 is switched On. Solonoid S1 is switched Off. S2 is switched On.
Drive (line pressure) oil from the manual valve engages the C2 clutch.
When S1 switches off , S1 oil pressure, which is derived from line 500 pressure, moves the 3-4 shift valve to
the left. At the same time S1 oil is directed to the 1-2 shift valve which moves the valve to the second gear position.
2nd oil (line pressure) from the 1-2 shift valve is directed to the band apply regulator valve, and to the 2-3 shift
valve.
The band apply regulator valve supplies 2nd oil (regulated to line pressure multiplied by the valve ratio) to the
band apply feed (BAF) circuit.
Band apply feed oil is directed to:
- The outer apply area of the front servo- The 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear - The 3-4 shift valve for use when the transmission is shifted into fourth gear
Drive (line pressure) is routed through the 3-4 shift valve to apply the C4 clutch.
Refer to figure 5.5 and table 5.6.
Table 5.6 - Engaged Elements - Drive 2 and Manual 2
Gear State
Drive 2 and Manual 2 C1
- C2
X C3
- C4
X B1
X B2
- 1-2
OWC - 3-4
OWC X LU
CLUTCH -
ELEMENTS ENGAGED

5A-54 AUTOMATIC TRANSMISSION POWER FLOW - DRIVE 3 AND MANUAL 3
In Drive 3 and Manual 3, transmission drive is via the input shaft to the forward clutch cylinder. The elements of the transmission function as follows : The C2 clutch is engaged to drive the forward sun gear.
The C1 clutch is engaged to drive the planet carrier.
The forward sun gear and the planet carrier are driven clockwise at the same speed therefore there is no
relative motion between the sun gear and the pinions.
The ring gear and output shaft are driven in a clockwise or forward direction at input shaft speed.
The C4 clutch is applied to bypass the 3-4 OWC and provide engine braking on overrun.
Control
To maintain this arrangement in the steady state solenoids and valves are activated as follows: Solenoid S1 is switched Off. S2 is switched Off.
With S1 and S2 switched Off, the 2-3 and 3-4 shift valves are held in the third gear position by line 500
pressure.
The 1-2 shift valve is held in the third gear position by S1-S2 oil pressure.
2nd oil (line pressure) from the 1-2 shift valve is directed to the band apply regulator valve. and to the 2-3 shift
valve.
The band apply regulator valve supplies 2nd oil (regulated to line pressure multiplied by the valve ratio) to the
band apply feed (BAF) circuit.
Band apply feed oil is directed to:
- The outer apply area of the front servo
- The 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear
- The 3-4 shift valve for use when the transmission is shifted into fourth gear
2nd oil at the 2-3 shift valve is directed to the 3rd oil circuit.
3rd oil from the 2-3 shift valve is directed to the clutch apply regulator valve, and to the 4-3 Sequence Valve.
The clutch apply regulator valve supplies oil (regulated to line 500 pressure multiplied by the valve ratio) to the
clutch apply feed (CAF) circuit.
The CAF oil is directed to:
- The C1 clutch- The C1 bias valve- The 4-3 sequence valve
At the 4-3 sequence valve the CAF oil becomes band 1 release feed (B1R-F) oil, and is directed through the
3-4 shift valve to the spring end of the 4-3 sequence valve, and to the release side of the front servo piston to hold band 1 off.
Drive (line pressure) is routed through the 3-4 shift valve to apply the C4 clutch.
Refer to figure 5.6 and table 5.7.
Table 5.7 - Engaged Elements - Drive 3 and Manual 3
Gear State
Drive 3 and Manual 3 C1
X C2
X C3
- C4
X B1
- B2
- 1-2
OWC - 3-4
OWC X LU
CLUTCH -
ELEMENTS ENGAGED

5A-56 AUTOMATIC TRANSMISSION POWER FLOW - DRIVE 3 LOCK UP AND MANUAL 3 LOCK UP
In Drive 3 Lock Up and Manual 3 Lock Up, transmission drive is the same as for Drive 3 but with the application of the
converter lock up clutch to provide positive no-slip converter drive. Control
Control for Drive 3 Lock Up and Manual 3 Lock Up is the same as for Drive 3 with the addition of the converter clutch circuit activated by solenoid S7. When S7 is switched On, S7 feed oil to the converter clutch control valve is switched off and allowed to exhaust
through the S7 solenoid. This allows the valve to move to the clutch engage position.
Regulated apply feed oil, derived from line 500 oil at the converter clutch regulator valve, is directed by the
converter clutch control valve to the engage side of the converter clutch.
Converter clutch release oil is exhausted at the converter clutch control valve.
Converter feed oil is re-routed by the converter clutch control valve directly to the oil cooler and lubrication
circuit.
Refer to figure 5.7and table 5.8.
Table 5.8 - Engaged Elements - Drive 3 Lock Up and Manual 3 Lock Up
Gear State
Drive 3 Lock Up and Manual 3 Lock Up C1
X C2
X C3
- C4
X B1
- B2
- 1-2
OWC - 3-4
OWC X LU
CLUTCH X
ELEMENTS ENGAGED