SSANGYONG NEW ACTYON SPORTS 2012 Service Manual

01-473680-01
12) Neutral (N)
Connecting Components ▶
Gear
ratioON / OFF solenoids Variable pressure sol. valve-VBS
S1 S2 S3 S4 S5(A) S6(A) S7(A) S8(A) S9(A) S10(A)
N/A ON ON ON 0-1
Gear
ratioEngaged element
C1 C2 C3 B1 B2 OWC Lock-up
clutch
AO AI R AO AI
N/A
Power Flow Diagram ▶

01-48
Neutral ▶

02-33170-01
Description Specification
Gear ratio 1st 4.489 : 1
2nd 2.337 : 1
3rd 1.350 : 1
4th 1.000 : 1
5th 0.784 : 1
6th 0.679 : 1
Reverse 4.253 : 1
Synchronizer
ring type1st T: Triple-cone
2nd T: Triple-cone
3rd T: Triple-cone
4th S: Single-cone
5th D: Double-cone
6th S: Single-cone
Reverse T: Triple-cone
Shifting Type Floor change type
Gear selector
lever position
Transmission
fluidType HD MTF 75W/85 (SHELL) or HK MTF 75W/85(SK)
Capacity
Sercive interval Inspect and replenish every 60000 km or 3 years (under
severe driving conditions, change every 120,000 km)
1. SPECIFICATION
Reversing:
High-force type
What’s the severe conditions?
Towing a trailer or off-road driving (Inspect
the leak of fluid at any time, occasionlly)
Taxi, patrol service or delivery service
(extended idling and excessive driving with
low speed)
Frequent stop-and-go traffic, extended
idling, short driving distance -
-
-Driving in a hilly or mountainous terrain,
sandy, or dusty area
Driving frequently at high speed over 170
km/hour
Driving frequently in area where heavy
traffic under the ambient temperature
above 30°C -
-
-

02-4
Part No. & Name Appearance Description
Part No.: SSM00203-
005
Name:
Main shaft 1st sleeve
installer
Part No.: SSM00203-
006
Name:
Main shaft reverse
sleeve installer
Part No.: SSM00203-
002
Name:
Main shaft 5th sleeve
installer
Part No.: SSM00203-
003
Name:
Oil seal installerInstall the extension housing oil seal
Part No.: SSM00203-
004
Name:
Oil seal installerInstall the control shaft oil seal
2. SPECIAL SERVICE TOOLS
Install the main shaft reverse sleeve and
bearing
Install the main drive pinion assembly front
ball bearing
Install the main shaft double angular ball
bearing
Install the 3rd & 4th synchronizer hub
Install the main shaft 5th gear
Install the main shaft 6th gear -
-
-
-
-
-Install the main shaft 1st gear sleeve
Install the drive pinion assembly front ball
bearing
Install the main shaft double angular ball
bearing -
-
-
Install the main shaft 5th gear sleeve
Install the counter shaft 6th gear sleeve
Install the counter shaft reverse gear
Install the main shaft ball bearing -
-
-
-

02-53170-01
Part No. & Name Appearance Description
Part No.: SSM00203-
001
Name:
Counter shaft bearin
g
installerInstall the counter shaft front roller bearing
Part No.:
T88310011A-9
Name:
Bearing supportSupport the counter shaft when removing the
roller bearing with a puller

02-6
3. TIGHTENING TORQUE
Part nameTightening torque
(Nm)Numbers Adhesive
1. Seal bolt (rolling plunger and guide spring) 53.9~67.6 1EA Loctite
2. Guide bolt 14.7~21.5 1EA Loctite
3. Pocket ball bearing bolt 29.4~41.1 1EA Loctite
4. Reverse shift fork retainer bolt 53.9~67.6 2EA Loctite
5. Backup lamp switch 29.4~34.3 1EA Loctite
6. Oil drain plug 58.8~78.4 1EA Loctite
7. Interlock bolt 14.7~21.5 1EA -
8. Neutral switch 29.4~34.3 1EA Loctite
9. Oil filler plug 58.8~78.4 1EA Loctite
10. Extension housing bolt 42.1~53.9 12EA -
11. Concentric slave cylinder bolt 9.8~15.6 3EA -
12. Front bearing retainer bolt 19.6~24.5 8EA Loctite

02-73170-01
3163161-00 Housing ▶
Case - Transmission
Retainer - Bearing
Bolt - Seal (19.6 ~ 24.5 Nm)
Seal - Oil
Bushing
Spacer
Gasket
Plug (58.8 ~ 78.4 Nm)
Gasket
Plug 2.
3.
4.
5.
6.
7.
8.
9.
10.
11.Breather - Air
Pulg - Seal (53.9 ~ 67.6 Nm)
Cylinder assembly - Concentric slave
Plunger - Rolling
Boot
Guide - Oil
Spring - Guide
Bolt - Flange (42.1 ~ 53.9 Nm) 12.
13.
14.
15.
16.
17.
18.
19.

02-8
3162-00 Main shaft ▶

02-93170-01
Ring - Snap
Ring - Snap
Bearing - Ball
Pinion assembly - Main drive
Bearing - Needle roller
Ring - Synchronizer
Ring - Snap
Sleeeve - Synchronizer
Key assembly - Synchronizer
Hub - Synchronizer
Ring assembly - Triple cone
Gear assembly - 3rd speed
Bearing - Needle roller
Shaft - Main
Gear assembly - 2nd speed
Bearing - Needle roller
Ring assembly - Triple cone
Hub - Synchronizer
Sleeeve - Synchronizer 1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.Ring assembly - Triple cone
Gear assembly - 1st speed
Sleeve - 1st gear
Bearing - Double angular ball
Ring - Snap
Gear - Main shaft 5th
Spacer
Gear - Main shaft 6th
Sleeve - Reverse gear
Bearing - Needle roller
Gear assembly - Reverse speed
Ring assembly - Triple cone
Hub - Synchronizer
Sleeeve - Synchronizer
Stopper - Synchronizer key
Bearing - Ball
Flange assembly - Companion
O-ring
Nut - Locking (4WD: 245.1 ~ 264.7 Nm,
2WD: 117.6 ~ 137.2 Nm) 20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.

02-10
33163-00 Counter shaft ▶
Ring - Snap
Bearing - Roller
Gear - Counter shaft
Gear - Counter shaft cluster
Bearing - Roller
Sleeve ?- Speed gear
Bearing - Needle roller
Gear assembly - 5th speed
Key assembly - Synchronizer
Ring assembly - Triple cone 1.
2.
3.
4.
5.
6.
7.
8.
9.
10.Hub - Synchronizer
Sleeeve - Synchronizer
Ring - Synchronizer
Sleeve - Speed gear
Bearing - Needle roller
Gear assembly - 6th speed
Gear - Counter shaft
Nut - Locking (156.9 ~ 186.3 Nm)
Bearing - Needle roller 11.
12.
13.
14.
15.
16.
17.
18.
19.