SSANGYONG KORANDO 1997 Service Repair Manual

5A-176 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
Planet Carrier Assembly and Centre Support
1. Check the carrier and planet assembly for any
damage or irregularity and ensure that all pinions
rotate freely and that the pinion end float is within
0.10 mm - 0.50 mm.
2. Install the One Way Clutch (OWC) retainer (1) to
the planet carrier with the inner edge pointing down-
wards. Inspect the OWC race and the sprag
assemblies for wear or damage. Replace if
necessary.
3. Install the outer (3) race in the drum. Press the
race to the bottom of the drum and install the
retaining circlip (2). Ensure the circlip is firmly
seated in its groove.
4. Install the OWC (1) into the outer race with the lip
edge uppermost. Lubricate the sprags with auto-
matic transmission fluid.
5. Check that the plugs are fitted to the centre
support, then assemble the centre support into
the OWC, ensuring that the support will rotate in
an anti-clock-wise direction only.
6. Lubricate the No. 9 needle bearing and washer
with petroleum jelly and fit them to the rear face
of the planet carrier.
7. In s t a l l th e
KAA5A0A0
KAA5A760
KAA5A750
KAA5A560
Tightening Torque20 - 27 Nm
(15 - 20 lb-ft)

AUTOMATIC TRANSMISSION 5A-177
SSANGYONG MY2002
Adaptor Housing Assembly
1. Install a new seal to the adaptor housing.
2. Position a new gasket onto the adaptor housing.
Notice: Do not use petroleum jelly to hold the gasket
in position.
3. Apply additional Loctite 202 or equivalent as required
to the adapter housing bolts. Install the adaptor
housing and torque the bolts to specification.
Installation Notice
Front Servo Assembly
1. Lubricate the cover ‘O’ ring with automatic
transmission fluid and fit to the cover.
2. Lubricatethepiston‘O’ rings with automatic trans-
mission fluid and fit to the piston.
3. Assemble the piston, push rod, spring, belleville
washer, seat and retaining ring.
4. Fit the piston push rod assembly into the front
servo cover.
5. Install the front servo block and spring into the
case.
6. Install the front servo assembly into the case.
KAA5A0C0
KAA5A520 KAA5A0B0
Tightening Torque30 - 35 Nm
(22 - 26 lb-ft)
7. Compress the servo cover and fit the servo cover
retaining circlip, aligning the gap with the pan rail,
and ensuring that it is completely seated in its
groove.
Notice: Ensure that the front servo snap ring is
installed correctly. Orient the circlip with the gap at
the bottom, near the pan rail.
KAA5A0D0

5A-178 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
4. Install the front band into the transmission case,
ensuring that it is properly seated in place.
Notice: If fitting a new band, soak the band in
automatic transmission fluid for a minimum of 5
minutes prior to assembly.
5. Position the reaction strut in its retaining clip and
engage it with the band and anchor strut.
6. Position the apply strut in its retaining clip and
engage it with the band and the servo piston rod.
C2/C4 Clutch Assembly
Tools Required
0555-336259Clutch Spring Compressor
0555-336260Clutch Pack Clearance Kit
Notice:
Check pistons for cracks.
Do not mix the clutch piston return springs.
Ensure that the snap rings are fitted correctly.
1. Check the feed orifices in the cylinder bore are clear
of obstructions.
2. Check the C2 piston bleed orifices are clear of
obstructions.
3. Lubricate the ‘O’ rings with Automatic Transmission
Fluid (ATF)
4. Fit the small ‘O’ ring onto the inner groove, and
the large ‘O’ ring onto the outer groove of the
piston.
Notice: ‘O’ rings must not be twisted in the grooves.
KAA5A0E0
KAA5A550
KAA5A0F0
Front Band Assembly
1. Install the reaction anchor strut to the case.
2. Check the band for all cracks or damage along its
lining and metal backing.
3. Position the strut retainers on the band.

AUTOMATIC TRANSMISSION 5A-179
SSANGYONG MY2002
5. Check the C4 piston bleed orifices are clear of
obstructions.
6. Lubricate the ‘O’ rings with ATF.
7. Fit the small ‘O’ rings onto the inner groove and
the large ‘O’ rings onto the outer groove of the
piston.
8. Position the clutch cylinder with the C2/C4 cavity
facing upwards.
9. Fit the C4 piston into the C2 piston with the bleed
orifices in alignment.
10. Install the C2/C4 piston assembly into the
cylinder, with the piston bleed orifices aligned with
the holes on the outside of the cylinder, until the
outer diameter of the C2 piston enters the inner
diameter of the cylinder.
KAA5A0G0
11. Assemble the piston return spring to the piston,
and fit the spring retainer over the spring.
12. Using 0555-336259 clutch spring compressor,
compress the spring sufficiently to enable the
installation of the retaining circlip ensuring that
the circlip is firmly seated in its groove, then
remove the tool.
Notice: The wire diameter of this spring is 4.3 mm.
13. Check the C1 piston check valves are not
damaged and are free to move, and that the
cylinder feed orifices are clear of obstructions.
14. Lubricate the ‘O’ rings with ATF and fit them to
their respective grooves.
Notice: ‘O’ rings must not be twisted in the
grooves.
KAA5A690

5A-180 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
15. Position the cylinder with the C1 cavity upwards.
Install the piston into the cylinder until the outer
diameter of the piston enters the inner diameter
of the cylinder.
16. Install the spring and spring retainer onto the
piston.
17. Using 0555-336259 clutch spring compressor,
compress the spring sufficiently to enable the
installation of the retaining circlip ensuring that
the circlip is firmly seated in its groove, then
remove the tool.
Notice: The wire diameter of this spring is 5.26 mm.
18. Install the C2 wave washer into the cylinder with
the crest of one wave covering one of the bleed
orifices inthe C2 piston.
19. Measure and record the thickness of the flange of
the C2 sleeve.
20. Install the C4 clutch plates and wave washer into
the C2 actuating sleeve, with the rounded edge
of the steel plates down, in the following
sequence:
Steel plate (selective)
Friction disc
Steel plate
Friction disc
Steel plate
Friction disc
Steel plate
Wave washer
KAA5A0H0
KAA5A0I0

AUTOMATIC TRANSMISSION 5A-181
SSANGYONG MY2002
21. Holding the cylinder horizontal, install the sleeve
and clutch plate assembly into the cylinder, with
the crest of one wave of the washer in line with
one of the holes in the outside of the cylinder,
until the sleeve contacts the C2 wave washer.
22. Check the C4 clutch pack clearance using 0555-
336260 clutch pack clearance kit.
Notice: With the C2 wave spring compressed, and
the clutch Pack supporting a 2 kg weight, the
dimension from the underside of the C2 pressure plate
to the selective steel is to be between 1.4 - 1.8 mm. If
the clutch is to be gauged from the top of the pressure
plate, then the dimension is to be the actual thickness
of the pressure plate plus 1.4 - 1.8 mm.
23. Use selective plates to achieve the correct
specification. If new friction plates are being fitted,
remove the clutch pack and soak the friction plates
in ATF for a minimum of 5 minutes prior to reassembly.
Notice: The clutch pack clearance must be taken
before the elements are soaked in ATF.
KAA5A0K0KAA5A0J0
24. Reassemble the sleeve and clutch pack into the
cylinder. Observe the alignment of the wave
washer to the hole in the cylinder.
25. Install the C2 clutch plates in the cylinder in the
following sequence:
Friction disc
Steel plate
Friction disc
Steel plate
Steel plate (0574-000013, `014, `015, `016,
`019, `022), or Friction disc (0574-000012 & `017)
Steel plate (selective)
Friction disc
Steel plate (selective)
Friction disc
KAA5A0L0

5A-182 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
26. Check the clutch pack clearance using only the
weight from 0555-336260 clutch pack clearance
kit.
Notice: With the clutch pack supporting a 2
kgweight, the dimension from the C3 clutch hub
locating step to the friction plate is to be between
0.80 - 1.05 mm.
27. Use selective plates to achieve the correct
specifica-tion. If new friction plates are being
fitted, remove the clutch pack and soak the friction
plates in ATF for a minimum of 5 minutes prior to
reassembly.
Notice: The clutch pack clearance must be taken
before the elements are soaked in ATF.
28. Lubricate and fit the 3-4 OWC and end caps to
the C2 hub.
32. Apply petroleum jelly to the No. 5 needle bearing
and fit it to the C4 hub.
33. Remove the C2 clutch plates from the clutch cylin-
der.
34. Fit the thrust plate over the cylinder inner hub.
35. Engage the C2/C4 clutch hub assembly in the C4
clutch plates.
36. Install the C2 clutch plates.
37. Install the C3 hub and secure it with the circlip,
ensuring that the circlip is firmly seated in its
groove. 29. Align the tangs and fit the nylon thrust washer
onto the C4 hub.
30. Align and fit the C4 hub to the C2 clutch and the
OWC assembly.
31. Check the rotation of the C2 hub. While holding
the C4 hub, the C2 hub should rotate in the
clockwise direction and lockup in the anti-
clockwise direction when viewed from the C2 hub.
KAA5A0M0
KAA5A0N0
KAA5A0O0

AUTOMATIC TRANSMISSION 5A-183
SSANGYONG MY2002
C3 Clutch and Reverse Sun Gear Assembly
Tools Required
0555-336259Clutch Spring Compressor
0555-336260Clutch Pack Clearance Kit
1. Check the orifices in the cylinder are clear of ob-
structions.
2. Check the C3 cylinder bush outside diameter and
the centre support inside diameter are in good
condition and not damaged. Coat the sealing rings
with automatic transmission fluid and fit into the
C3 cylinder grooves.
3. Check the reverse sun gear splines, grooves and
thrust face for condition. Coat the ‘O’ ring with
automatic transmission fluid and fit it to the groove
of the reverse sun gear.
4. Lubricate the C3 washer with petroleum jelly and
fit to the inner face of the reverse sun gear.
5. Install the reverse sun gear in the C3 cylinder,
ensuring that the ‘O’ ring compression is
adequate but not excessive.
Notice: ‘O’ rings must not be twisted in the
grooves.
KAA5A0P0
6. Coat the C3 piston ‘O’ rings with automatic trans-
mission fluid and fit the small ‘O’ ring onto the
inner ring and the large ‘O’ ring onto the outer
ring of the C3 piston.
7. Check that the bleed orifices of the piston are
clean and clear of obstructions.
8. Install the C3 piston in the cylinder until the
outside diameter of the piston enters the inside
diameter of the cylinder.
Notice: Take care not to cut the ‘O’ ring.
9. Assemble the spring and spring retainer on the
piston. Using 0555-336259 clutch spring
compressor compress the spring sufficiently to
enable the installation of the retaining circlip,
ensuring that the circlip is firmly seated in the
groove, and remove the tool.
10. Fit the C3 wave plate to the C3 piston face,
ensuring that one crest of the wave plate of the
C3 piston face is aligned over one of the piston
orifices.
KAA5A0Q0
KAA5A730

5A-184 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
11. Assemble the clutch plates and discs into the
cylinder in the following sequence :
Steel plate
Friction disc
Steel plate
Steel plate (0574-000013, `014, `015, `016, `019,
`022), or Friction disc (0574-000012, `017)
Steel plate (selective)
Friction disc
Steel plate (selective)
Friction disc
12. Align and fit the pressure plate with the
counterbore facing away from the clutch plates.
13. Install the circlip.
14. Check the C3 clutch clearance using 0555-336260
clutch pack clearance kit in the following manner
(weight only).
a. Place the weight on the pressure plate and
measure the distance from the end of the
cylinder to the top of the pressure plate.
b. Record this figure.
c. Remove the weight.
d. Lift the pressure plate up against the circlip
and measure the distance from the end of the
cylinder to the top of the pressure plate.
e. Record this figure.
f. Subtract the second reading from the first read-
ing to obtain the clutch pack clearance.KAA5A0R0
KAA5A0S0

AUTOMATIC TRANSMISSION 5A-185
SSANGYONG MY2002
Notice: With the clutch pack supporting a weight
of 2kg, the clearance between the snap ring and
the top of the pressure plate is to be between 1.07
- 1.45 mm.
15. If new friction plates are being fitted, remove the
clutch pack and soak the friction elements in auto-
matic transmission fluid for a minimum of five min-
utes prior to reassembly.
Notice: The clutch pack clearance must be taken
before the elements are soaked in automatic
transmission fluid.
Forward Sun Gear and C3 Clutch Pack
Assembly
1. Fit the No. 7 needle bearing assembly over the
for-ward sun gear, ensuring that the thrust washer
is between the bearing and the sun gear.
2. Lubricate the lipped thrust plate with petroleum
jelly and fit the thrust plate onto the reverse sun
gear.
KAA5A0U0 KAA5AOTA
3. Align and fit the C3 clutch assembly over the for-
ward sun gear.
4. Lubricate the No. 6 needle bearing with petroleum
jelly and fit it to the thrust plate. Ensure the lugs
on the outside diameter of the bearing fit in the
thrust plate counterbore.
5. Align and fit the plastic thrust washer to the thrust
plate with petroleum jelly.
6. Install the assembly over the forward sun gear
shaft against the No. 6 needle bearing.
7. Place the assembly to one side.
KAA5A0W0KAA5A0V0