engine SSANGYONG KORANDO 1997 Service Repair Manual

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)

5A-206 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
TCM WIRING DIAGRAM (GASOLINE ENGINE - 1
SCHEMATIC AND ROUTING DIAGRAMS
KAA5A010

AUTOMATIC TRANSMISSION 5A-207
SSANGYONG MY2002
TCM WIRING DIAGRAM (GASOLINE ENGINE - 2 OF 2)
KAA5A020

5A-208 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
TCM WIRING DIAGRAM (DIESEL ENGINE - 1 OF 2)
YAD5A230

AUTOMATIC TRANSMISSION 5A-209
SSANGYONG MY2002
TCM WIRING DIAGRAM (DIESEL ENGINE - 2 OF 2)
YAD5A240

SSANGYONG MY2002
5B-4 MANUAL TRANSMISSION
DIAGNOSTIC INFORMATION AND PROCEDURES
Control lever assembly broken or dam-
aged.
Damaged offset lever, shift fork, selector
place or selector arm.
Clutch not releasing.
Improper or low transmission oil.
Shift or shift rail binding.
Binding of sliding synchronizers or gears.
If reverse only, faulty backup switch.
Worn or damaged flywheel pilot bushing.
Engine idle speed too high.
Damaged or faulty clutch.
Pilot bearing between input shaft and
output shaft binding.
Damaged synchronizer.
Bell housing misaligned.
Damaged gear(s).
Worn or damaged flywheel pilot bushing.
Loosened transmission or flywheel
housing bolts, improper alignment.
Synchronizer damaged or excessively
worn.
Blocking ring damaged, worn index slots
or friction surfaces worn or damaged.
Excessive countershaft end play.
Worn or damaged fork due to loosened
shaft, rail or shifting fork.
Fork or offset lever loose on shaft or rail.
Worn or damaged forks, offset lever,
shaft or rail.Replace control lever and housing assem-
bly.
Remove extension, adapter or case
cover. Check or replace damaged parts.
Adjust or replace clutch.
Add or replace with specified oil.
Remove extension, adapter or case
cover. Check or replace damaged parts.
Remove extension, adapter or case
cover. Check synchronizers and gears
and replace damaged parts.
Check or replace backup switch.
Replace pilot bushing.
Adjust idle speed to specified speed.
Adjust or replace clutch.
Replace or check roller bearings.
Check or replace synchronizer parts.
Align bell housing and bore.
Check or replace gear(s).
Replace pilot bushing.
Tighten bolts to specified value. Realign
if necessary.
Check or replace synchronizer parts.
Check or replace blocking ring.
Check worn or damaged parts. Adjust
shim thickness using roller bearings if
necessary.
Check for wear or damaged. Replace
worn or damaged parts.
Replace extension, adapter or case
cover. Check or replace loose parts on
shaft or rail. Replace roll pin(s).
Remove extension, adapter or case
cover. Check for wear or damaged.
Replace damaged parts. Check Applicatio
Will not shift
(control lever moves)
Hard shift or control
lever will not move into
gear
Gears crash when
shifting
Transmission jumps
out
Transmission locked in
one gear
Action

MANUAL TRANSMISSION 5B-5
SSANGYONG MY2002
Check worn or damaged synchronizer
parts and replace if necessary.
Check worn or damaged gears and
replace if necessary.
Add or drain and replace with proper oil.
Tighten as specified.
Realign correctly.
Check bearings, bearing rollers and parts
for wear or damage. Replace if neces-
sary.
Check for worn or damaged
gears(including speedometer gear).
Replace if necessary.
Clean all exposed surfaces, then check
for leaks.
Clean or replace vent or breather.
Check oil level.
Tighten as specified.
Clean leaking surfaces. Reapply sealant.
Replace oil seal.
Action
Worn or damaged synchronizer.
Worn or damaged gears.
Improper or low transmission oil.
Loose bolts or other attaching parts.
Improper flywheel housing to engine
crankshaft alignment.
Noisy transmission bearing.
Noisy gears.
Leakage from transmission.
Vent or breather clogged.
Too much oil.
Loose bolts at sealing faces.
Improperly applied sealant.
Worn or damaged oil seal.Check Applicatio
Transmission locked in
one gear
Transmission noise
Transmission leakage

SSANGYONG MY2002
5B-20 MANUAL TRANSMISSION
7. Remove the front and rear propeller shafts from
the transfercase.
8. Support the transmission on an suitable jack.
Unscrew the center mounting nuts and each sides
mounting bolts and remove the cross member.
9. Remove the transmission mounting bolts.
Notice: For removing the transmission, there may
be any damage in the clutch housing inside CSC.
Thus remove the transmission with the clutch
housing.
10. Move the transmission jack backward careful and
disengage the transmission input shaft from the
engine.
Remove the transmission.
YAD5B320
YAD5B330
YAD5B340
YAD5B020

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

SSAMGYONG MY2002
5C-6 CLUTCH
CLUTCH DISC
Preceding Work : Removal of the transmission
KAA5C040
1 Clutch Disc
2 Clutch Cover Assembly
3 Release Bearing
4 Clutch Housing5 Washer
6 Bolt........................................... 23 Nm (17 lb-ft)
7 Washer
8 Bolt........................................... 54 Nm (40 lb-ft)
Tools
602 589 00 40 00 Engine Lock
661 589 00 15 00 Centering Pin