SSANGYONG KORANDO 1997 Service Repair Manual

5A-186 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
KAA5A0X0
C1 Clutch Overdrive Shaft and Input Shaft
Assembly
Tools Required
0555-336260Clutch Pack Clearance Kit
Notice:
Ensure that the snap rings are fitted correctly.
Check pistons for cracks, especially the C1 piston.
Do not mix clutch piston return springs.
If the C1/C2 clutch packs separate from the C3
clutch pack, make sure the No. 6 bearing doesn’t
drop out of the bearing retainer.
1. Check the overdrive shaft grooves for any defect.
2. Coat the sealing rings, large and small, with petro-
leum jelly and fit them to the overdrive shaft. The
sealing rings may be held in place with a small
amount of petroleum jelly.
3. Assemble the clutch plate and disc into the cylinder
in the following sequence:
Steel plate
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
4. Check the clutch pack clearance using 0555-
336260 clutch pack clearance kit.
5. Use selective plates to achieve the correct
specification.
Notice: With the clutch pack supporting a 2 kg
weight, the dimension from the input shaft locating
stop to the friction disc must be 0.70 - 0.90 mm.
6. 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
minutes prior to assembly.
Notice: The clutch pack clearance must be taken
before elements are soaked in automatic
transmission fluid.
KAA5A0X0
KAA5A0Y0
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AUTOMATIC TRANSMISSION 5A-187
SSANGYONG MY2002
7. Check the fit of the C1 clutch hub on the overdrive
shaft. If it is loose, the hub and shaft assembly
must be replaced.
8. Coat the small nylon thrust spacer with petroleum
jelly and install it over the overdrive shaft.
9. Carefully fit the overdrive shaft into the C1 cylinder
so as not to damage the sealing ring.
10. Fit the small bronze C1 hub thrust washer in place
with petroleum jelly.
11. Check the input shaft for any defect. Fit the input
shaft into the cylinder and secure it with the circlip,
ensuring that the circlip is completely seated in
the groove.
KAA5A660
12. Coat the sealing rings with petroleum jelly and fit
onto the input shaft.
KAA5A1A0
13. Assemble the C1/C2/C4 clutch assembly to the
C3 clutch and sun gear assembly.
14. Install this assembly in the transmission case.
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5A-188 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
Pump Cover and Converter Support
Notice:
Do not wash the nose of solenoids in solvent.
Ensure that the correct ‘O’ ring is fitted for the
application.
Be careful not to damage the needle bearings on
the assembly. Avoid any axial impact loads during
assembly.
Check the transmission end float. This will help to
detect any missing parts or incorrect assembly.
1. Check the pump body for any damage, chips or
irregularity. Check that the bush is firmly staked
in the drive gear.
2. Install the seal flush with the front face of the
pump body.
3. Lubricate the pump bush, and the drive and driven
gears, with automatic transmission fluid.
4. Install the pump driven gear and the pump drive
gear into the pump body.
5. Using a straight edge and thickness gauge, check
that the clearance between pump face and gears
is 0.04 - 0.018 mm.
6. Lubricate the pump body ‘O’ ring with automatic
transmission fluid and fit it to the pump body. Put
the pump body to one side.
7. Ensure that the pump cover cavities, ports and
holes are clean and free of any obstruction.
8. Lubricate all loose parts with automatic
transmission fluid prior to assembly.
KAA5A1C0
KAA5A810
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AUTOMATIC TRANSMISSION 5A-189
SSANGYONG MY2002
11. Install the converter clutch regulator valve, plug,
spring and ‘O’ ring. 9. Assemble the primary regulator valve, spring and
plunger to the pump cover, ensuring that the
regulator valve slides freely, then fit the regulator
valve plug and ‘O’ ring.
10. Install the retaining pin.
KAA5A1F0 KAA5A1E0
12. Install the retaining pin.
KAA5A1G0
13. Install the converter clutch control valve, spring,
plug, and ‘O’ ring.
14. Install the retaining pin.
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5A-190 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
15. Install the converter release check ball and spring.
16. Install the gasket on the pump cover.
17. Install the cover plate, solenoid 7 with the retainer
and the solenoid wiring retainer to the pump cover,
ensuring that the periphery of the cover plate is
flush with the periphery of the pump cover.
18. Tighten the screws to specification in the order.
(1-5)
Installation Notice
20. Assemble the pump to the pump cover.
21. Tighten all bolts and the crescent screw finger
tight, ensuring that the pump is flush against the
pump cover. Tighten the bolts and the screw to
specification in the order. (A-F)
Installation Notice 19. Tighten the solenoid 7 screw.
Installation Notice
Check that neither the wiring nor the connector
protrudes excessively, in order that at
assembly neither the wiring and the connector
contacts or rubs on the input shaft or the C1/
C2 clutch cylinder.
22. Install the pump to transmission case gasket onto
the case.
23. Fit the ‘O’ ring to the pump cover outer diameter.
KAA5A1J0
KAA5A1K0
KAA5A1L0
Tightening Torque13 - 16 Nm
(10 - 12 lb-ft)
Tightening Torque13 - 16 Nm
(10 - 12 lb-ft)
Tightening
TorqueBolt (A-E) : 24 - 27 Nm
(18 - 20 lb-ft)
Screw (F) : 13 - 16 Nm
(10 - 12 lb-ft)

AUTOMATIC TRANSMISSION 5A-191
SSANGYONG MY2002
24. Install the pump and cover assembly over the
input shaft being careful not to damage the sealing
rings. Apply additional Loctite 202 or equivalent
as required to the pump cover to case bolts.
Install and tighten bolts to specification.
Installation Notice
KAA5A1M0
Tightening Torque24 - 34 Nm
(18 - 25 lb-ft)
25. Check that the transmission end float is 0.50 -
0.65 mm. If the unshimmed end float clearance is
greater than specification, shims are to be placed
between the No. 4 bearing and the input shaft
bearing surface. If the end float clearance is less
than 0.5 mm then the transmission has been
assembled incorrectly or the parts are out of
specification.
26. Perform the following steps to check the end float :
a. Attach a dial indicator to the front of the trans-
mission case with the stylus resting on the end
of the input shaft.
b. Apply a force of approximately 250 N or 25 kg
to the input shaft.
c. Zero the dial indicator.
d. Place a small lever behind the forward clutch
cylinder and lever the cylinder forward.
e. The measurement recorded on the dial indicator
is the transmission end float or clearance be-
tween the No. 4 bearing and the converter sup-
port tube.
27. On completion of this procedure, adjust the front
and rear bands to specifications. Refer to “Front
and Rear Band Adjustment” in this section.
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5A-192 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
Valve Body
Notice:
Do not wash the nose of solenoids in solvent.
Be aware of ball positions in the upper valve body.
Be aware of 1 - 2 and 3 - 4 shift valve positions,
they can be swapped.
Check the 4 - 3 sequence valve and spring
orientation.
Check that the 12 mm ball is in the lower body.
Check the line pressure relief valve for swarf, and
be aware of replacing the shims.
When servicing the transmission, ensure that the
solenoid 5 damper spring is not broken.
Locate the detent spring central to the detent lever.
Wash the upper and lower valve bodies thoroughly
with cleansing solvent and blow dry.
Check the valve body cavities, ports and holes for
damage or obstructions.
The orifices in the valve body are for stability and
safeguard. Do not drill them larger.
Thoroughly wash all loose components.
Check that all valves slide freely in their location.
1. Install the detent lever locating pin
2. Install the Band Apply Regulator (BAR) valve,
springs, plunger and retaining pin.
3. Install the line pressure relief valve, tapered end
first, spring and disc. Secure with the retaining pin.
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AUTOMATIC TRANSMISSION 5A-193
SSANGYONG MY2002
6. Install the 1 - 2 shift valve, plug and retaining pin.
7. Install the 2 - 3 shift valve and retaining pin. 4. Install the solenoid 5 damper guide and spring,
piston and retaining pin.
5. Install the 4 - 3 sequence valve, spring, plug and
retaining plate.
KAA5A1R0 KAA5A1Q0KAA5A860 KAA5A870

5A-194 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
8. Install the 3 - 4 shift valve and retaining pin.
9. Install the Clutch Apply Regulator (CAR) valve,
springs, plunger and retaining pin.
10. Install the solenoid supply valve, spring and
retaining plate.
Notice: This aluminum valve is easily damaged.
11. Install solenoid 6 plunger, spring and retaining
pin.
12. Position the third feed ball (large nylon) in the valve
body and install the solenoid 6 filter.
13. Check the separator plate for burrs and damage.
Repair or replace the separator plate as
necessary.
14. Check the upper and lower valve body gaskets
for damage. Replace the gaskets as necessary.
15. Install the lower valve body gasket on the lower
valve body.
KAA5A1S0
KAA5A1T0
KAA5A1U0
KAA5A850

AUTOMATIC TRANSMISSION 5A-195
SSANGYONG MY2002
19. Holding the separator plate to the upper valve
body to prevent the check balls from falling out,
install the upper valve body on the lower valve
body. Install all screws finger tight then tighten
the screws to specification in the prescribed
sequence.
Installation Notice
The wiring loom ground wire eyelet terminal is
secured beneath the solenoid 1 retainer. 16. Install the reverse lockout valve, spring, plug and
retaining plate. Ensure that the valve is correctly
oriented.
17. Position the five nylon ball checks in the upper
valve body.
18. Fit the upper valve body gasket. Install the
separator plate over the upper valve body.
KAA5A830 KAA5A840 KAA5A1V0
Tightening Torque11 - 16 Nm
(8 - 12 lb-ft)
20. Install solenoids 1, 2, 3, 4 and 6. Ensure the
solenoid is firmly secured by the retainer and that
the screw is tightened to specification.
Installation Notice
8 - 12 Nm
(71 - 106 lb-in)