torque SSANGYONG KORANDO 1997 Service Repair Manual

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.
KAA5A1N0

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)

5A-196 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
21. Install solenoid 5. Ensure that the solenoid is
pushed firmly into the valve body by the retainer
and that the screw is tightened to specification.
Installation Notice
22. Install the detent spring assembly (spring, support
plate and screw), ensuring that the screw is tight-
ened to specification. Check the spring for wear
or damage.
Installation Notice
23. Install the manual shift valve.
Notice: Be aware that the manual valve will fall out
of the valve body.
24. Align the valve body assembly on the
transmission case and install the manual valve
lever to manual valve link. Fit the long end of the
link to the manual valve first. Install the securing
bolts and tighten to specification in the specified
sequence.
Installation Notice
KAA5A1Y0 KAA5A1X0
KAA5A1Z0 KAA5A1W0
Tightening Torque8 - 12 Nm
(71 - 106 lb-in)
Tightening Torque20 - 22 Nm
(15 - 16 lb-ft)
Tightening Torque8 - 13 Nm
(71 - 115 lb-in)

AUTOMATIC TRANSMISSION 5A-197
SSANGYONG MY2002
2. Carefully assemble the oil filter to the valve body.
The spigot must not lean on one side while being
fitted.
3. Secure the oil filter assembly with the retainer.
4. Check that the magnet is located in the dimple in
the corner of the oil pan.
5. Assemble the gasket on the pan lip. The gasket
must be free of any distortion when installed. 25. Check the alignment of the detent roller and the
manual lever quadrant.
26. Connect the solenoid wiring as detailed below:
Solenoid 1 - red
Solenoid 2 - bIue
Solenoid 3 - yellow
Solenoid 4 - orange
Solenoid 5 - green
Solenoid 6 - violet
Notice: All hardware must be correctly installed and
torqued to specification.
Oil Filter and Pan Assembly
Notice:
Replace the filter whenever rebuilding a
transmission where a significant amount of
mechanical damage has occurred.
To aid the assembly of the pan gasket, use a small
amount of Vaseline at the pan/gasket interface. This
ensures that the gasket remains on the pan ridge.
Do not over torque pan bolts as this may distort
the pan and cause leaks.
Ensure that the internal line pressure plus in the
valve body is fitted.
1. Lubricate the oil filter sealing ring with automatic
transmission fluid.
KAA5A2B0 KAA5A2A0
KAA5A510

5A-198 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
Torque Converter and Housing Assembly
1. Locate the torque converter housing on the trans-
mission main case.
2. Apply additional Loctite 202 or equivalent as
required to the converter housing to case bolts.
Install and tighten bolts to specification.
Installation Notice
All the hardware must be correctly installed and
torqued to specification.
3. Fit the converter ensuring that the tangs are
engaged in the pump gear. Ensure that the tangs
do not contact the pump seal.
Output Flange Assembly (2WD Mode)
1. Position the transmission detent lever into the park
position and lock the output shaft.
2. Clear the threads on the output shaft and apply
Loctite 243 or equivalent as required to threads.
3. Install the flange, ‘O’ ring and torque the nut to
specification.
Installation Notice
6. Fit the oil pan assembly to the transmission case
and tighten the securing bolts to specification and
sequence. Do not over torque.
Installation Notice
KAA5A2C0
KAA5A2D0
KAA5A040
Tightening Torque4 - 6 Nm
(35 - 53 lb-in)
Tightening Torque54 - 68 Nm
(40 - 50 lb-ft)
Tightening Torque 35 Nm (26 lb-ft)

AUTOMATIC TRANSMISSION 5A-203
SSANGYONG MY2002
SPECIFICATIONS
GENERAL SPECIFICATION
Model Specifications
Clutch Pack Details Model Part Numbers And Applications
Descriprtion
260 mm (10.2 in.)
2.0 : 1
2.741 : 1
1.508 : 1
1.000 : 1
0.708 : 1
2.429 : 1
Castrol TQ95
9.0 Liters (approx.)
4.5 Liters (approx.)
0.50 - 0.65 mm (0.020 - 0.026 in.)
0.10 - 0.50 mm (0.004 - 0.020 in.)Application
Torque Converter
Mean Diameter of Fluid Circuit Description
Maximum Torque Multiplication
Gear Ratios
First
Second
Third
Fourth
Reverse
Lubricant
Type
Capacity
Dry System
Service Refill
Gear Train End Float
Gear Set Pinion End Float
Transmission
0574-000013
0574-000012Torque Converter
179K
150K Engine Version
E23
E32 SYMC P/NO
36100-05442
36100-05432
C1
Composition
Steel
C2
Composition
Steel
C3
Composition
Steel
C4
Composition
Steel
0574-000012 (13)
5 (4)
5 (6)
5 (4)
4 (5)
4 (3)
4 (5)
3 (3)
4 (4)

AUTOMATIC TRANSMISSION 5A-205
SSANGYONG MY2002
FASTENER TIGHTENING SPECIFICATIONS
N•m
35 - 40
16 - 22
20 - 27
20 - 22
54 - 68
70 - 80
4 - 6
40 - 45
4 - 6
8 - 12
35
13 - 16
13 - 16
24 - 34
24 - 27
70 - 80
30 - 35
54 - 68
42
35 - 60
30 - 35
11 - 16
8 - 13
8 - 12Lb-Ft
26 - 30
12 - 16
15 - 20
15 - 16
40 - 50
52 - 59
-
29 - 33
-
-
26
10 - 12
10 - 12
18 - 25
18 - 20
52 - 59
22 - 26
40 - 50
31
26 - 44
22 - 26
8 - 12
-
- Application
Adaptor Housing to Case Bolts
Cam Plate to Case (Parking Pawl) Screws
Centre Support to Case Bolts
Detent Spring Screw
Extension Housing to Case Bolts
Front Propeller Shaft Bolts
Inhibitor Switch to Case Bolts
Oil Cooler Pipes
Oil Pan to Case Bolts
On/Off Solenoid Retainer Screws
Output Flange Nuts
Pump Cover Plate to Crescent Screw
Pump Cover Plate to Pump Cover Screws
Pump Cover to Case Bolts
Pump to Pump Cover Bolts
Rear Propeller Shaft Bolts
Rear Servo Cover to Case Bolts
Torque Converter Housing to Case Bolts
Torque Converter Mounting Bolts
Transfer Case to Transmission Housing Bolts
Transmission Filler Plug
Upper Valve Body to Lower Valve Body Screws
Valve Body To Case Bolts
Variable Pressure Solenoid (S5) Retainer ScrewLb-Ft
-
-
-
-
-
-
35 - 53
-
35 - 53
71 - 106
-
-
-
-
-
-
-
-
-
-
-
-
71 - 115
71 - 106

SSANGYONG MY2002
5B-22 MANUAL TRANSMISSION
62 - 93 Nm
(45 - 69 lb-ft)
21 - 35 Nm
(15 - 26 lb-ft)
Check the housing face alignment.
- Place the dial indicator on the housing face.
- By rotating the crankshaft one revolution,
record the dial indicator reading.
Notice: If the reading is greater than 0.010 inch,
insert the shim between the engine and clutch
housing and adjust the alignment.
5. Check the following parts :
Pressure plate spring assembly
Disc
Flywheel
Input shaft pilot bearing
Notice: Replace the excessively worn parts.
6. Lubricate the clutch release bearing bore, fork
pivot head during assembly.
Installation Procedure
1. Install the transmission to the vehicle. At this time,
seat correctly the input shaft of the transmission
on the pilot bearing of the flywheel.
2. Tighten the transmission mounting bolts as the
specified torque on the vehicle.
Installation Notice
YAD5B390
YAD5B400
YAD5B410
YAD5B420
Tightening Torque77 - 87 Nm
(57 - 64 lb-ft)
3. Install the cross member and tighten as the
specified torque by supporting the suitable jack.
Installation Notice
Tightening
TorqueLeft/Right
Center

MANUAL TRANSMISSION 5B-23
SSANGYONG MY2002
4. Install the front and rear propeller shafts to the
transmission.
Installation Notice
5. Connect the cable, the harness and the bleeder.
6. Install the back lamp switch.
7. Install the speedometer cable.
YAD5B430
YAD5B440
YAD5B450
YAD5B310
81 - 89 Nm
(60 - 66 lb-ft)
70 - 90 Nm
(52 - 66 lb-ft)
Tightening
TorqueFront
Rear
8. Charge the approved oil in the transmission
housing and tighten the drain plug and the filler
plug.
Installation Notice
Oil25 Nm (18 lb-ft)
25 Nm (18 lb-ft)
Tightening
TorqueFiller Plug
Drain Plug
Spec.
Capacity
3.4L
2.0L
4WD
2WDATF Dexron II