section 2c SSANGYONG KORANDO 1997 Service Repair Manual

AUTOMATIC TRANSMISSION 5A-135
SSANGYONG MY2002
DTC P1742 Solenoid 2 Circuit Short
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
3. Checks if the S2 circuit in the transmission is
malfunctioning.
4. Check cable in the transmission for short to
ground.
6. Check resistance between S2 terminal A and B.
Standard value is 22 - 30 Ω.
9. Check connections of other connectors.If diagnosing for a possible intermittent short or
open condition, move or massage the wiring
harness while observing test equipment for a
change.
Solenoid Logic for Static Gear States
Gear
1st
2nd
3rd
4th
Reverse
Neutral
ParkS1
ON
OFF
OFF
ON
OFF
OFF
OFFS2
ON
ON
OFF
OFF
OFF
OFF
OFF
1Perform a Transmission Control Module (TCM) System
Check.
Is the check performed?
1. Install the scan tool.
2. Turn the ignition ON, with the engine OFF.
3. Record and then clear DTCs.
4. Operate the vehicle within the conditions for
setting this DTC as specified in the text.
Does the scan tool display P1742?
1. Turn the ignition OFF.
2. Disconnect the 10-way transmission connector.
(additional DTCs will set)
3. Connect Solenoid/Thermistor Electrical Tester
(STET) to the 10-way transmission connector of
transmission side and to the good ground.
4. Turn the mode knob of STET to 2 and push the red
button.
Does the bulb of close circuit on the solenoids side of
STET illuminate?
1. Remove the valve cover. Refer to the Transmission
in this section.
2. With a test light connected to B+, probe the wiring
harness from 10-way transmission connector to
Solenoid 2 (S2) on the valve body.
Does the test light illuminate?
Repair the short to ground in the wiring harness.
Is the repair complete?
Using a Digital Volt Meter (DVM), measure the
resistance between S2 terminal A and B.
Is the resistance within the specified value?
Replace the S2.
Is the action complete?
StepAction Value(s) Yes No
2
3
- Go to Step 2 Go to “TCM
Diagnostic
System Check”
- Go to Step 4 Go to Step 8
5
6 4
- Go to Step 5 Go to Step 6
- Go to Step 11 -
7
- Go to Step 11 -
20 - 30 ΩGo to
“Diagnostic
Aids”
Go to Step 7
- Go to Step 3Go to
“Diagnostic
Aids”

AUTOMATIC TRANSMISSION 5A-139
SSANGYONG MY2002
DTC P1743 Solenoid 3 Circuit Short
If diagnosing for a possible intermittent short or
open condition, move or massage the wiring
harness while observing test equipment for a
change.
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.3. Checks if the S3 circuit in the transmission is mal-
functioning.
4. Check cable in the transmission for short to
ground.
6. Check resistance between S3 terminal A and B.
Standard value is 22 - 30 Ω.
9. Check connections of other connectors.
- Go to Step 11 - 1Perform a Transmission Control Module (TCM) System
Check.
Is the check performed?
1. Install the scan tool.
2. Turn the ignition ON, with the engine OFF.
3. Record and then clear DTCs.
4. Operate the vehicle within the conditions for
setting this DTC as specified in the text.
Does the scan tool display P1743?
1. Turn the ignition OFF.
2. Disconnect the 10-way transmission connector.
(additional DTCs will set)
3. Connect Solenoid/Thermistor Electrical Tester
(STET) to the 10-way transmission connector of
transmission side and to the good ground.
4. Turn the mode knob of STET to 3 and push the red
button.
Does the bulb of close circuit on the solenoids side of
STET illuminate?
1. Remove the valve cover. Refer to the Transmission
in this section.
2. With a test light connected to B+, probe the wiring
harness from 10-way transmission connector to
Solenoid 3 (S3) on the valve body.
Does the test light illuminate?
Repair the short to ground in the wiring harness.
Is the repair complete?
Using a Digital Volt Meter (DVM), measure the resis-
tance between S3 terminal A and B.
Is the resistance within the specified value?
Replace the S3.
Is the action complete?
1. Disconnect the TCM connector A.
2. With a test light connected to B+, probe the wiring
harness from 10-way transmission connector
terminal 3 to TCM terminal A10.
Does the test light illuminate?
Check for a poor connection at the 10-way transmission
connector and TCM connector and repair the malfunc-
tioning terminals as necessary.
Is a repair necessary?
StepAction Value(s) Yes No
2
3
- Go to Step 2 Go to “TCM
Diagnostic
System Check”
- Go to Step 4 Go to Step 8
5
6 4
- Go to Step 11 -
7
8
9
- Go to Step 5 Go to Step 9
- Go to Step 11 Go to Step 10
- Go to Step 3Go to
“Diagnostic
Aids”
20 - 30 ΩGo to
“Diagnostic
Aids” Go to Step 7
- Go to Step 5 Go to Step 6

AUTOMATIC TRANSMISSION 5A-143
SSANGYONG MY2002
DTC P1744 Solenoid 4 Circuit Short
Inspect the wiring for poor electrical connections
at the TCM and at the 10-way transmission
connector. Look for possible bent, backed out,
deformed or damaged terminals. Check for weak
terminal tension as well. Also check for chafed wires
that could short to bare metal or other wiring.
Inspect for broken wire inside the insulation.
If diagnosing for a possible intermittent short or
open condition, move or massage the wiring
harness while observing test equipment for a
change.Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
3. Checks if the S4 circuit in the transmission is mal-
functioning.
4. Check cable in the transmission for short to
ground.
6. Check resistance between S4 terminal A and B.
Standard value is 22 - 30 Ω.
9. Check connections of other connectors.
- Go to Step 11 - 1Perform Transmission Control Module (TCM) System
Check.
Is the check performed?
1. Install the scan tool.
2. Turn the ignition ON, with the engine OFF.
3. Record and then clear DTCs.
4. Operate the vehicle within the conditions for
setting this DTC as specified in the text.
Does the scan tool display P1744?
1. Turn the ignition OFF.
2. Disconnect the 10-way transmission connector.
(additional DTCs will set)
3. Connect Solenoid/Thermistor Electrical Tester
(STET) to the 10-way transmission connector of
transmission side and to the good ground.
4. Turn the mode knob of STET to 4 and push the red
button.
Does the bulb of close circuit on the solenoids side of
STET illuminate?
1. Remove the valve cover. Refer to the Transmission
in this section.
2. With a test light connected to B+, probe the wiring
harness from 10-way transmission connector to
Solenoid 4 (S4) on the valve body.
Does the test light illuminate?
Repair the short to ground in the wiring harness.
Is the repair complete?
Using a Digital Volt Meter (DVM), measure the resis-
tance between S4 terminal A and B.
Is the resistance within the specified value?
Replace the S4.
Is the action complete?
1. Disconnect the TCM connector A.
2. With a test light connected to B+, probe the wiring
harness from 10-way transmission connector
terminal 4 to TCM terminal A4.
Does the test light illuminate?
StepAction Value(s) Yes No
2
3
-
Go to Step 2 Go to “TCM
Diagnostic
System Check”
- Go to Step 4 Go to Step 8
5
6 4
- Go to Step 5 Go to Step 6
- Go to Step 11 -
7
8
- Go to Step 5 Go to Step 9
- Go to Step 3Go to
“Diagnostic
Aids”
20 - 30 ΩGo to
“Diagnostic
Aids” Go to Step 7

AUTOMATIC TRANSMISSION 5A-147
SSANGYONG MY2002
DTC P1745 Solenoid 5 Circuit Short
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
3. Checks if the S5 circuit in the transmission is mal-
functioning.4. Check cable in the transmission for short to
ground.
6. Check resistance between S5 terminal A and B.
Standard value is 3.6 - 5.5 Ω.
10. Check connections of other connectors.
- Go to Step 12 - 1Perform Transmission Control Module (TCM) System
Check.
Is the check performed?
1. Install the scan tool.
2. Turn the ignition ON, with the engine OFF.
3. Record and then clear DTCs.
4. Operate the vehicle within the conditions for
setting this DTC as specified in the text.
Does the scan tool display P1745?
1. Turn the ignition OFF.
2. Disconnect the 10-way transmission connector.
(additional DTCs will set)
3. Connect Solenoid/Thermistor Electrical Tester
(STET) to the 10-way transmission connector of
transmission side.
4. Turn the mode knob of STET to 5 and push the red
button.
Does the bulb of close circuit on the solenoids side of
STET illuminate?
1. Remove the valve cover. Refer to the Transmission
in this section.
2. With a test light connected to B+ probe the wiring
harnesses from 10-way transmission connector to
Solenoid 5 (S5) on the valve body.
Does the test light illuminate?
Repair the short to ground in the wiring harness.
Is the repair complete?
Using a Digital Volt Meter (DVM), measure the resis-
tance between S5 terminal A and B.
Is the resistance within the specified value?
Replace the S5.
Is the action complete?
1. Disconnect the TCM connector A.
2. With a test light connected to B+, probe the wiring
harness from 10-way transmission connector
terminal 5 to TCM terminal.
Does the test light illuminate?
Probe the wiring harness from 10-way transmission
connector terminal 8 to TCM terminal A1.
Does the test light illuminate?
Check for a poor connection at the 10-way transmission
connector and TCM connector and repair the malfunc-
tioning terminals as necessary.
Is a repair necessary?
StepAction Value(s) Yes No
2
3
-
Go to Step 2 Go to “TCM
Diagnostic
System Check”
- Go to Step 4 Go to Step 8
5
6 4
- Go to Step 5 Go to Step 6
- Go to Step 12 -
7
8
9
- Go to Step 5 Go to Step 9
10
- Go to Step 5 Go to Step 10
- Go to Step 12 Go to Step 11
- Go to Step 3Go to
“Diagnostic
Aids”
3.6 - 5.5 ΩGo to
“Diagnostic
Aids” Go to Step 7

AUTOMATIC TRANSMISSION 5A-159
SSANGYONG MY2002
12. Remove the service hole cover in the engine block.
13. Put the alignment mark for installation, and
removethe six mounting bolts for torque converter
from drive plate through the service hole by
rotating the engine and remove the torque
converter.
Installation Notice
Screw the six bolts mounting the torque
converter through the service hole by using a
mirror and rotating the engine.
14. Remover the starter. Refer to Section 1E, Engine
Electrical.
15. Remove the extension housing to case bolts and
remove the transmission assembly.
Installation Notice
Be careful not to drop the torque converter while
removing the transmission.
16. Installation should follow the removal procedure
in the reverse order.
KAA5A2N0
KAA5A2O0
Tightening Torque54 - 68 Nm
(40 - 50 lb-ft)
Tightening Torque 42 Nm (31 lb-ft)

AUTOMATIC TRANSMISSION 5A-151
SSANGYONG MY2002
DTC P1746 Solenoid 6 Circuit Short
If diagnosing for a possible intermittent short or
open condition, move or massage the wiring
harness while observing test equipment for a
change.
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
3. Checks if the S6 circuit in the transmission is mal-
functioning.4. Check cable in the transmission for short to
ground.
6. Check resistance between S6 terminal A and B.
Standard value is 22 - 30 Ω.
9. Check connections of other connectors.
- Go to Step 11 - 1Perform a Transmission Control Module (TCM) System
Check.
Is the check performed?
1. Install the scan tool.
2. Turn the ignition ON, with the engine OFF.
3. Record and then clear DTCs.
4. Operate the vehicle within the conditions for
setting this DTC as specified in the text.
Does the scan tool display P1746?
1. Turn the ignition OFF.
2. Disconnect the 10-way transmission connector.
(additional DTCs will set)
3. Connect Solenoid/Thermistor Electrical Tester
(STET) to the 10-way transmission connector of
transmission side and to the good ground.
4. Turn the mode knob of STET to 6 and push the red
button.
Does the bulb of close circuit on the solenoids side of
STET illuminate?
1. Remove the valve cover. Refer to the Transmission
in this section.
2. With a test light connected to B+, probe the wiring
harness from 10-way transmission connector to
Solenoid 6 (S6) on the valve body.
Does the test light illuminate?
Repair the short to ground in the wiring harness.
Is the repair complete?
Using a Digital Volt Meter (DVM), measure the
resistance between S6 terminal A and B.
Is the resistance within the specified value?
Replace the S6.
Is the action complete?
1. Disconnect the TCM connector A.
2. With a test light connected to B+, probe the wiring
harness from 10-way transmission connector
terminal 6 to TCM terminal A12.
Does the test light illuminate?
Check for a poor connection at the 10-way transmission
connector and TCM connector and repair the malfunc-
tioning terminals as necessary.
Is a repair necessary?
StepAction Value(s) Yes No
2
3
-
Go to Step 2 Go to “TCM
Diagnostic
System Check”
- Go to Step 4 Go to Step 8
5
6 4
- Go to Step 5 Go to Step 6
- Go to Step 11 -
7
8
9
- Go to Step 5 Go to Step 9
- Go to Step 11 Go to Step 10
- Go to Step 3Go to
“Diagnostic
Aids”
20 - 30 ΩGo to
“Diagnostic
Aids” Go to Step 7

AUTOMATIC TRANSMISSION 5A-155
SSANGYONG MY2002
DTC P1747 Solenoid 7 Circuit Short
If diagnosing for a possible intermittent short or
open condition, move or massage the wiring
harness while observing test equipment for a
change.
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
3. Checks if the S7 circuit in the transmission is mal-
functioning.4. Check cable in the transmission for short to
ground.
7. Check resistance between S7 terminal A and B.
Standard value is 22 - 30 Ω.
10. Check connections of other connectors.
- Go to Step 15 Go to Step 7 1Perform a Transmission Control Module (TCM) System
Check.
Is the check performed?
1. Install the scan tool.
2. Turn the ignition ON, with the engine OFF.
3. Record and then clear DTCs.
4. Operate the vehicle within the conditions for
setting this DTC as specified in the text.
Does the scan tool display P1747?
1. Turn the ignition OFF.
2. Disconnect the 10-way transmission connector.
(additional DTCs will set)
3. Connect Solenoid/Thermistor Electrical Tester
(STET) to the 10-way transmission connector of
transmission side and to the good ground.
4. Turn the mode knob of STET to 7 and push the red
button.
Does the bulb of close circuit on the solenoids side of
STET illuminate?
1. Remove the pump assembly. Refer to the Pump in
this section.
2. With a test light connected to B+, probe the wiring
harness from 10-way transmission connector to
contact point attached onto the transmission case.
Does the test light illuminate?
Repair the short to ground in the wiring harness.
Is the repair complete?
With a test light connected to B+, probe the wiring
harness from contact point attached onto the trans-
mission case to S7.
Does the test light illuminate?
Using a Digital Volt Meter (DVM), measure the
resistance between S7 terminal A and B.
Is the resistance within the specified value?
Replace the S7.
Is the action complete?
1. Disconnect the TCM connector A.
2. With a test light connected to B+, probe the wiring
harness from 10-way transmission connector
terminal 7 to TCM terminal A9.
Does the test light illuminate?
StepAction Value(s) Yes No
2
3
-
Go to Step 2 Go to “TCM
Diagnostic
System Check”
- Go to Step 4 Go to Step 8
5
6 4
- Go to Step 5 Go to Step 6
- Go to Step 12 -
7
8
9
- Go to Step 12 -
- Go to Step 5 Go to Step 10
- Go to Step 3Go to
“Diagnostic
Aids”
20 - 30 ΩGo to
“Diagnostic
Aids”
Go to Step 8

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.
KAA5A1N0

5A-202 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
KICKDOWN SWITCH
1. Separate the Kickdown Switch from the Kickdown
Switch bracket by pushing the lock.
2. Disconnect the Kickdown Switch connector.
3. Installation should follow the removal procedure in
the reverse order.
KAA5A5S0
GEAR SHIFT CONTROL LEVER
Disassembly and Assembly Procedure
1. Disconnect the negative battery cable.
2. Remove the gear shift control lever assembly.
Refer to Section 9G, interior Trim.
3. Remove the gear shift control lever knob.
4. Separate the upper and middle housing from the
gear shift control lever assembly by unlocking the
lock.
5. Remove the upper housing.
6. Disconnect the P position lamp by turning it from
the middle housing.
7. Remove the P position switches assembly bolts.
8. Remove the middle housing with the mode
selector switch wiring harness from the gear shift
control lever assembly.
9. Separate the P position switches assembly with
the P position lamp wiring harness from the gear
shift control lever assembly.
Notice: Adjust the brake transmission shift interlock
ease the operation well.
10. Remove the clips supporting the springs and
bushes from the pin of the pin of the gear shift
control lever.
11. Remover the spring and bushes from the pin of
the gear shift control lever.
12. Remove the gear shift control lever by pushing
the pin.
13. Installation should follow the removal procedure
in the reverse order.
KAA5A5P0
KAA5A5Q0
KAA5A5R0

SECTION 5B
MANUAL TRANSMISSION
TABLE OF CONTENTS
General Description and Operation.....................5B-2
Shift Lever...........................................................5B-2
Transmission Assembly.......................................5B-2
Specifications......................................................5B-3
Diagnostic Information and Procedures..............5B-4
Diagnosis Table...................................................5B-6
Component Locator............................................5B-7
Cross-Sectional View ...........................................5B-7
Power Flow..........................................................5B-8
Seni-Remote Kit Disassembly and Assembly.......5B-9
Transmission Assembly.....................................5B-10
Transmission Assembly Disassembled View......5B-11Maintenance and Repair................................... 5B-14
On-Vehicle Service...............................................5B-14
Semi-Remote Kit................................................5B-14
Transmission.....................................................5B-19
Unit Repair.......................................................... 5B-24
Major Unit..........................................................5B-24
Main Shaft.........................................................5B-34
Input Shaft........................................................5B-38
Counter Shaft....................................................5B-40
Extension Housing.............................................5B-40
Shift Cover........................................................5B-41
Inspection of Components.................................5B-45