clutch SSANGYONG MUSSO 2003 Repair Manual

AUTOMATIC TRANSMISSION 5A-57
POWER FLOW - DRIVE 4 (OVERDRIVE)
In Drive 4 (Overdrive), transmission drive is via the input shaft to the forward clutch cylinder. The elements of the transmission function as follows :
The C1 clutch is applied to drive the planet carrier clockwise.
The B1 band is applied to hold the reverse sun gear stationary.
As the planet carrier tuns, the long pinion ‘walks ’ around the stationary reverse sun gear and rotates around its
axis driving the internal ring gear and output shaft in a clockwise or forward direction at a speed faster than the input shaft i.e. in overdrive ratio.
The forward sun gear is also driven faster than the input shaft and overruns the 3-4 OWC.
The C2 clutch is engaged to reduce the speed differential across the 3-4 OWC.
Control
To maintain this arrangement in the steady state solenoids and valves are activated as follows: Solenoid S1 is switched On. S2 is switched Off.
With S1 switched On the 3-4 shift valve is held in the fourth gear position by line 500 pressure on the small end
of the valve.
With S2 switched Off the 2-3 shift valve is held in the fourth gear position by line 500 pressure on the large end of the valve.
The 1-2 shift valve is held in the fourth gear position by 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 inner apply area of the front servo piston via the 3-4 shift valve
- the 1-2 shift valve to provide an exhaust port when the transmission is shifted to first 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
Drive oil (line pressure) from the manual valve engages the C2 clutch
Refer to figure 5.8 and table 5.9.
Table 5.9 - Engaged Elements - Drive 4 (Overdrive)
Gear State
Drive 4 (Overdrive) C1
X C2
X C3
- C4
- B1
X B2
- 1-2
OWC - 3-4
OWC X LU
CLUTCH -
ELEMENTS ENGAGED

AUTOMATIC TRANSMISSION 5A-59
POWER FLOW - DRIVE 4 LOCK UP
In Drive 4 Lock Up, transmission drive is the same as for Drive 4 but with the application of the converter lock up clutch
to provide positive no-slip converter drive. Control
Control for Drive 4 Lock Up is the same as for Drive 4 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, delved 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 5.9 arid table 5.10.
Table 5.10 - Engaged Elements - Drive 4 Lock Up
Gear State
Drive 4 Lock Up C1
X C2
X C3
- C4
- B1
X B2
- 1-2
OWC - 3-4
OWC - LU
CLUTCH X
ELEMENTS ENGAGED

AUTOMATIC TRANSMISSION 5A-65
If the gear lever is incorrectly adjusted, the transmission may shift gears on bumpy road surfaces.
6 Transmission Oil Temperature Sensing FaultAll shifts will be firm until the transmission has warmed up, because a high transmission oil temperature is
assumed.
If a fault is undetected, the temperature is likely to be evaluated as being lower than actual, resulting in softer shifts with ‘end bump ’ (very firm feel at the end of the shift).
7 Mode Setting Fault All shifts will occur as if the mode is set to ‘NORMAL ’ .
The mode indicator will always be off indicating that ‘NORMAL ’ mode is selected.
The mode indicator will not respond to changes in switch setting.
If a fault is undetected, the mode as indicated by the mode indicator is not likely to respond to the mode switch.
8 Battery Voltage Sensing Fault
If the battery voltage is low then shifts to first gear are inhibited.9 the battery voltage is high (>16.5V) then the transmission goes into limp home (LHM) mode.
If a fault is undetected, the transmission is likely to incorrectly evaluate an ON/OFF solenoid fault resulting in limp home mode (LHM) operation.
9 ON/OFF Solenoid Fault (Solenoids 1,2,3 and 4)
The transmission adopts its limp home mode (LHM) operation, described above. However, if solenoid 1 is faulty then
the fourth gear LHM strategy will be adopted independent of vehicle speed.
If a fault is undetected, the operation of the transmission is dependent on which solenoid is actually faulty. The
characteristics for different solenoid fault conditions are listed in table 6.1.2.
10 ON/OFF Solenoid Fault (Solenoids 6,7)
If solenoid 6 is found faulty it is always disabled resulting in high line pressure being applied continuously.
If solenoid 7 is found faulty it is disabled resulting in the transmission being locked always.The transmission does not go into LHM.
11 Variable Pressure Solenoid Fault The transmission adopts its LHM operation.
If a fault is undetected, the transmission shift feel is likely to be poor for all shifts.
12 Software Fault
The transmission adopts the third gear LHM strategy of operation, independent of vehicle speed. The operation of
the TCU under this condition is difficult to predict. Its operation may be erratic.
If a fault is undetected, the operation of the TCU is likely to be erratic.
13 Power Supply Fault
The transmission adopts the third gear LHM strategy of operation, independent of vehicle speed. If there is an
intermittent power supply connection, the TCU will power-up in fourth gear and then shift to the appropriate gear to
satisfy the conditions present. The power supply is not monitored for fault evaluation.
All faults except for solenoid faults can be recovered without having to turn the TCU off and back on. However, in
general the recovery requires that no faults are present for a period of time (approx. 3 or 30 seconds). Recovery from
a fault will not clear the fault from the keep alive memory
14 Transmission Sump Temperature Exceeding 135°C
The converter lockup clutch will be applied at lower speeds, causing a shudder through the vehicle.
The mode indicator will flash in some vehicles.
These faults can be due to the transmission oil overheating or due to an incorrect signal received from the temperature
sensor.

AUTOMATIC TRANSMISSION 5A-69
MECHANICAL TESTS
In Vehicle Transmission Checks
Carry out the following tests before removing the transmission. See Checking Transmission Fluid Level, Section 7.2.1.
Check that the transmission oil is not burnt (colour and smell are correct).
Ensure that the transmission is not in limp home mode (LHM).
Check that the battery terminals and the earth connections are not corroded or loose.
Check the engine stall speed is within the handbook value.
Check that the cooler flow is not restricted.
Check that all electrical plug connections are tight.
Carry out a road test to confirm the symptoms, if necessary.
Inspect the oil, ensure that there are no metal or other contaminants in the oil pan.
Diagnosing Oil Leaks
Determine the source of oil leaks by firstly cleaning down the affected area, then driving the vehicle. Inspect the seals to confirm the source of the leak. To determine the source of a rear servo oil leak, raise the vehicle on a hoist, then carry out a reverse stall.
To determine the source of a front servo leak, raise the vehicle on a hoist, then run the vehicle in second gear.
Troubleshooting Charts The troubleshooting charts are set out as follows: Table 6.2.1 Drive Faults,
Table 6.2.2 Faulty Shift Patterns.
Table 6.2.3 Shift Quality Faults.
Table 6.2.4 After Teardown Faults.
Table 6.2.1 - Drive Faults
Action
Check the fluid level. Top up as necessary. Inspect and clean C1/C2 feed. Reinstall/renew the ‘z’ link.
Remove, clean and re-install the PRV.
Inspect and replace as necessary.
Inspect and replace as necessary.
Inspect and replace as necessary.
Check servo adjustment or replace rear band
as necessary.
Check for failure in C3, C3 hub or C1/C2 cylin-
der. Repair as necessary.
Inspect and clean PRV.
Inspect and replace pump gears as necessary.
Inspect and repair as necessary.
Possible Cause
Insufficient auto transmission fluid.
Blocked feed in C1/C2 cylinder.
‘Z’ link displaced.
Primal regulator valve (PRV) jammed open.Overdrive shaft or input shaft seal ringsfailed. 3-4 or 1-2 one way clutch (OWC) installed backwards or failed.C2 piston broken or cracked.
Rear band or servo faulty.
Failure in C3, C3 hub or C1/C2 cylinder.Jammed primary regulator valve (PRV). Damaged/broken pump gears. Dislodged output shaft snap ring.Symptom
No Drive in D No Drive in ReverseNo engine braking
in Manual 1 Engine braking in Manual 1 is OKNo drive in Driveand Reverse

5A-70 AUTOMATIC TRANSMISSION
Action
Inspect S1. Repair or replace as necessary.
Check for 12 Volts applied to S1 at all times orfor wiring fault.
Inspect S1. Repair or replace as necessary.
Check for 12 Volts applied to S1 at all times or for wiring fault.
Inspect S2. Repair or replace as necessary.
Check for open circuit or wiring fault.
Inspect S2. Repair or replace as necessary. Check for open circuit or wiring fault.
Inspect and adjust as necessary.
Inspect and repair as necessary.
Inspect and replace or refit as necessary. Inspect ‘O’ ring. Refit or replace as nec essary.
Inspect the 2-3 shift valve. Repair or replace
as necessary.
Inspect C1 clutch. Repair or replace as neces-
sary.
Inspect ball. Refit or replace as necessary. Inspect C4. Repair C4 or replace C4 wave plate
as necessary.
Inspect rear band adjustment. Adjust as nec-
essary.
Inspect ball- Refit or replace as necessary. Inspect ’0’ring. Refit or replace as necessary.
Inspect C4 and C4 wave plate. Repair or re-
place as necessary.Inspect inhibitor switch. Repair or replace as necessary.
Inspect the 1-2 shift valve.
Repair or replace as necessaryInspect inhibitor switch.Repair or replace as necessary.
Inspect the 2-3 shift valve.Repair or replace as necessary.
Possible Cause
S1 always OFF. S1 always ON.
S2 always OFF. S2 always ON. B1 failed. Loose band adjustment.Front servo piston or seal failed.S1/S2 ball misplaced, Smaller ’0’ring on front servo piston failed
or missing. 2-3 shift valve jammed.C1 clutch failed or slipping in 3rd and 4th.(Gives 1st in 3rd and 2nd in 4th.) Over-run clutch (OC)/low ball misplaced. C4 failed or C4 wave plate broken. Rear band slipping when hot. Reverse/Low-1st ball misplaced. Rear servo inner ‘O’ ring missing.
C4 failed or C4 wave plate broken.
Inhibitor switch faulty. 1-2 shift valve jammed.
Inhibitor switch fault, 1-2 only. 2-3 shift valve jammed.Symptom
2-3 shift only
(no 4th or 1st)
1-4 shift only1-3-4 (Delayed1-2shift)4-3 shift only 1-2-Neutral
(1st over run)1-3 shift only 1-3-4 only 1-2-1 only No manual 4-3,3-2
or 2 - 1 No manual 1st 1st gear only or
2nd,3rd, and 4thonly 1st and 2nd only or 1st, 3rd and 4th
only

AUTOMATIC TRANSMISSION 5A-71
Table 6.2.2 - Faulty Shift Patterns
Action
Inspect inhibitor switch. Repair or replace as
necessary.
Inspect the 3-4 shift valve. Repair or replace
as necessary.
Inspect the release valve. Repair or replace as
necessary.
Inspect S3 or S2. Repair or replace as neces-
sary.
Inspect the regulator valve. Repair or replace
as necessary.
Inspect the ball. Refit or replace as necessary.
Inspect the sealing rings. Refit or replace as
necessary.Inspect the ‘O’ rings. Refit or replace as neces-
sary.
Inspect the bleed ball. Refit or replace as nec-
essary.
Inspect S1 or S4. Repair or replace as neces-
sary.
Inspect the release valve. Repair or replace as
necessary.
Inspect the band. Adjust as necessary. Inspect the ‘O’ rings. Refit or replace as neces-
sary.
Inspect S5. Repair or replace as necessary.
Inspect the regulator valve. Repair or replace
as necessary.
Possible Cause
Inhibitor switch fault, 1-2-3 only. 3-4 shift valve jammed. Jammed band 1 release valve. Faulty S3 or S2 solenoid. Faulty clutch apply regulator valve.Missing or damaged clutch apply feed ball. Damaged input shaft sealing rings. Damaged C1 piston ‘O’ rings.
Damaged or dislodged C1 piston bleed ball. Faulty S1 or S4 solenoid.
Jammed band 1 release valve. Incorrect front band adjustment. Damaged front servo piston ‘O’ rings.
Faulty or damaged variable pressuresolenoid (S5). Faulty band apply regulator valve.Symptom
1st,2nd and 4th
only or 1st,2nd,
and 3rd (tied up in3rd) Harsh 2-3 shift Harsh 3-4 shift

5A-72 AUTOMATIC TRANSMISSION
Action
Drain and fill with specified ATF.
Check that S5 is fitted correctly, or replace S5.
Inspect band apply and clutch apply regulator
springs. Refit or replace as necessary.
Inspect the ball. Refit or replace as necessary.
Inspect C4 clutch. Replace or repair as neces-
sary.
Check the alignment. ]Realign as necessary.
Inspect wave plate. Replace as necessary.
Inspect S5 and replace as necessary.
Inspect the damper spring and replace as nec-
essary.
Replace spring as necessary.
Check the clearance and adjust as necessary.
Inspect C4. Repair or replace as necessary.
Inspect piston. Repair or replace as necessary.
Inspect and adjust band as necessary. Replace the plug. Replace the spring.Replace the spring/plug.Refit the ball.
Inspect the clutch. Repair the clutch as neces-
sary. Inspect and clean C1 feed.Replace the piston.
Inspect and replace the sealing rings and/or
shaft as necessary. Inspect and replace the ball.
Inspect and replace the sealing rings and/or
shaft as necessary.
Inspect and repair the C1 clutch as necessary.Refit the valve. Replace the ball.
Possible Cause
Incorrect auto transmission fluid (ATF).
S5 faulty won, or incorrectly fitted.Band apply and clutch apply regulatorsprings misplaced. Over-run clutch (OC)/Low-1st ball misplaced.C4 clutch worn or burnt. C4 wave plate not lined up with the holes in the piston. C4 wave plate failed.S5 worn.S5 damper spring broken. Front servo belleville spring broken. Incorrect C4 pack clearance.Damaged C4 clutch.Cracked C2 piston (leaking into C4).Incorrect band adjustment Front servo plastic plug missing B1R spring broken.B1R spring/plug left out.C1/B1R ball misplaced.C1 clutch damaged. Restriction in C1 feed. C1 piston check ball jammed.
Overdrive or input shaft sealing rings dam-aged. C1/B1R ball misplaced.
Overdrive or input shaft sealing rings dam-aged.C1 clutch damaged.4-3 sequence valve in backwards. Low-1st check ball misplaced.Symptom
All Shifts Firm Manual 4-3-2-1 is soft delayed or
missing Firm 1-2 Hot
4th Tied up
Tied up on 2-3Flare on 2-3 Slips in 4th Flare on 4-3, Flare on 3-2Firm Manual low
shift-high line press.

AUTOMATIC TRANSMISSION 5A-73
Table 6.2.3 - Shift Quality Faults
Action
Check the resistance. Replace the inhibitor
switch as necessary.
Inspect and replace the sensor as necessary.
Inspect and adjust the band as necessary.Inspect and replace the ’0’rings as necessary.
Inspect, repair or replace S5 as necessary.
Inspect, repair or replace S1 or S4 as neces-
sary.
Inspect, repair or replace the BAR as neces-
sary.
Inspect and repair as necessary.
Inspect and clean CCCV.
Inspect, repair or replace as necessary.
Possible Cause
Faulty inhibitor switch.
Faulty throttle position sensor. Incorrect front band adjustment.Damaged front servo piston ’0’rings.
Faulty or damaged variable pressure so- lenoid (S5). Faulty S1 or S4 solenoid. Faulty band apply regulator valve (BAR). Misassembled front servo return spring. Jammed converter clutch control valve(CCCV).Faulty solenoid 7.Symptom
Harsh 1-2 shift stalls when Drive
or Reverse selected Shudder
on Rolldown

5A-74 AUTOMATIC TRANSMISSION
Action
Inspect, repair C2 and adjust the linkage as neces-
sary. Repair C2. Inspect, repair or replace S6 as neces-
sary.Repair C2. Inspect, replace the sealing rings and/
or shaft as necessary. Repair C2. Inspect, repair or replace the C2 piston
as necessary.
Inspect C4 and repair as necessary.Inspect and adjust the C4 pack clearance as nec-
essary. Repair C4. Inspect and replace the wave plate as
necessary.Repair C4. Inspect and realign the wave plate as
necessary.Repair C4. Inspect and realign the sealing rings
and/or shaft as necessary. Repair C4. Inspect and refit the OWC as neces-
sary.Repair C4. Inspect and replace the C2 piston as
necessary.
Repair C4. Inspect and refit the ball as necessary.Inspect and repair B1 and replace the spring as
necessary.Replace sealing ring.
Repair B1. Refit the ball as necessary. Inspect and repair C1 and replace the spring.Repair C1. Inspect and replace the sealing tongs
and/or shaft as necessary.Repair C1. Inspect and replace the C1 piston as
necessary. Repair C1. Inspect and refit the capsule as neces-
sary.Repair C1. Inspect and refit the valve as neces-
sary. Repair C1. Inspect and replace the ball as neces-
sary.
Inspect and adjust the band as necessary.
Inspect and refit the ball as necessary.Inspect and replace the ‘O’ ring as necessary.
Inspect and refit the valve as necessary.Inspect and replace the ‘O’ ring as necessary.
Inspect and refit the valve as necessary.
Possible Cause
T-bar linkage out of adjustment.
56 foiled - stuck low. Overdrive/output shaft sealing rings damaged. C2 piston cracked. Incorrect C4 pack clearance. C4 wave plate broken.
C4 wave plate not lined up properly.Overdrive or output shaft sealing rings dam- aged. 3-4 one way clutch (OWC) in backwards. C2 piston cracked. Over-run clutch (OC)/low-1st ball misplaced. B1R spring broken. Input shaft sealing ring cut. C1/B1R ball misplaced. B1R spring left out.Overdrive or input shaft sealing rings damaged. C1 piston cracked. Ball capsule jammed. 4-3 sequence valve in backwards. Clutch apply feed (CAF)/B1R ball left out. Rear band incorrectly adjusted or damaged. Reverse-low/first ball misplaced.Input shaft ‘O’ ring missing or damaged.
Converter clutch regulator valve in backwards.Input shaft ‘O’ ring missing or damaged.
C1 bias valve in backwards.
Symptom
C2 burnt C4 burnt B1 burnt C1 burnt Slips in reverse - no manual 1st Firm converter
lock or unlockNo lock up at lightthrottle
Table 6.2.4 - After Teardown Faults

5A-86 AUTOMATIC TRANSMISSION
9. Remove the pump to case bolts using a multi-hex 8 mmspanner.
10. Using the pump puller No. 0555-332941, remove the pump.
11. Remove the input shaft, forward clutch cylinder, and the overdrive shaft as an assembly, withdrawing them through the front of the case.
12. Remove the C3 clutch cylinder and sun gears.
13. Remove the fronts band struts. Remove the front band.
14. Remove the two centre support retaining bolts using a T50 Torx bit.
15. Remove the centre support retaining circlip. Notice
Do not hammer the output shaft to remove the centre
support as this will cause permanent damage to the thrust bearing surfaces.
16. Remove the centre support, 1-2 one way clutch, planetary gear set and output shaft as an assembly.
17. Remove the parking rod cam plate. (T40 Torx bit).
18. Remove the rear band struts and remove the band. 4. Detach each end of the filter retaining clip from the valve
body and remove the filter.
5. Detach the wires from each solenoid and lay the wiring to one side.
6. Remove the valve body securing screws and remove the valve body from the case.
7. Remove the front servo cover circlip. Remove the cover and piston.Notice
The plastic servo block is retained by the piston return
spring only.
8. Where fitted, remove the flange yoke, and then remove the extension housing (RWD model).
Remove the adaptor housing (4WD model).