manual transmission SSANGYONG KORANDO 2012 Service Manual

01-6
1. GUIDELINES FOR SERVICE WORKS
1) For Safety
To perform the service works easily ans safely, the service technicians must keep the proper working
procedures and rules.
This manual provides the useful instructions to the service technicians so that they can perform the
servive works with standard working process, skills, tips in time.
Please read this manual and follow the instructions carefully.
Signal words such as “CAUTION” and “NOTE” have special meanings.
indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury or property damage.
However, above references and cautions cannot be inclusive measures, so should have habits of
paying attentions and cautions based on common senses.
indicates information to assist maintenance and instructions.
2) Equipment
Korando is FF (Front Engine Front Drive) type vehicle, and engine and powertrain system are
integrated into a module. Therefore, 2-post lift and general equipment are necessary when working
on the engine and transmission.
Major equipment: Engine and transmission jack, Engine stand, Engine crane, Transmission jack,
Engine hanger -
-
Engine crane
Engine stand
Transmission
jack

01-70000-00
3) General Instructions
Before lifting up the vehicle with a lift, correctly support the lifting points.
When using a jack, park the vehicle on a level ground and place the wheel chocks under the tires.
Position the jack under the frame and lift up the vehicle and then support with chassis stand before
service work.
Make sure to disconnect the negative (-) cable from the battery to prevent any damage to electric
systems.
If you have to work on vehicle, cover the seats and floor with protection covers to avoid any
damage and contamination.
Brake fluid and anti-freeze can damage the painted surface of body. So carefully handle them
during service work.
To improve the efficiency of service work, use only recommended and specified tools.
Use only Ssangyong genuine spare parts.
Never reuse the cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace them
with new ones. If reused, normal functions cannot be maintained.
Store the disassembled parts as a set based on disassembly order and unit.
Pay particular attention not to miss or mix the fasteners.
If necessary, especially for inspection, clean the removed parts completely.
Apply the oil or grease on the running and sliding surfeces before installation. Use the specified
sealant and gasket to prevent leakage if necessary.
Tighten the fasteners to the specified tightening torque.
As a final stage of service work, check if the serviced system is working properly and the problem
has been eliminated clearly. (1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14) Remove the engine and transaxle as a set.
Manual transaxle: Transaxle can be separated after removing the front module (sub frame, engine
and transaxle).
Automatic transaxle: Transaxle can be separated after removing the sub frame. -
-
2) Equipment
Korando is FF (Front Engine Front Drive) type vehicle, and engine and powertrain system are
integrated into a module. Therefore, 2-post lift and general equipment are necessary when working
on the engine and transmission.
Major equipment: Engine and transmission jack, Engine stand, Engine crane, Transmission jack,
Engine hanger -
-

02-6
3. GUIDELINES ON ENGINE SERVICE
G20DF engine is for FF (Front Engine Front Drive) type vehicle. Therefore, there are some deferent
maintenance and repair works compared to the engine for FR (Front Engine Rear Drive) type vehicle.
For safe and correct works, you must observe the working procedures and instructions in this manual.
And, use the designated tools as follow:
: Power train mounting stand / Engine hanger / Engine stand / Heavy duty engine jack.
Cautions before service works ▶
G20DF engine is FF (Front Engine Front Drive) type engine, and the engine and transmission are
integrated in a same module. Remember that there are many differences compared to
conventional engine in FR (Front Engine Rear Drive) type SUV vehicle.
To remove the engine, use the dedicated equipments such as engine jack, transmission jack,
engine stand and engine crane (1 ton).
To prevent the engine from abruptly starting during service in engine compartment, never allow
anybody to stay in the vehicle.
Make sure to disconnect the negative (-) cable from the battery to prevent any damage to electric
systems.
Make sure to clean the working area and to prepare the necessary tools before service works.
Always place the ignition switch to OFF position if not required. Otherwise, there could be
unexpected damage to electric devices or personal injuries due to short-circuit..
To prevent the foreign material from entering into the fuel injection system, completely seal the
inlets of HP pump, fuel hoses and high pressure pipes.
Do not remove the engine while supporting the oil pan with a jack. -
-
-
-
-
-
-
Lifting up the vehicle ▶
Before lifting up the vehicle with a lift, correctly support the lifting points.
To prevent the vehicle from rolling down, put the chocks under the tires (when using a 4-post lift).
Make sure to support the correct lifting points (when using a 2-post lift). -
-
-

06-358510-00
3) Cruise Control Switch
Cruise control switch
The cruise control is an automatic speed control system that maintains a desired driving speed without
using the accelerator pedal. The cruise control switch is fitted to the bottom right section of the steering
wheel. When this switch is operated, the AUTO CRUISE or ECO lamp on the instrument cluster comes
on.
The cruise control switch has a fivefold switch in it. The engine ECU can determine the current driving
condition since the resistance varies depending on the operation of the switch.
The cruise control system is operated at vehicle speed of between 38 km/h and 150 km/h. The manual
transmission is operated in the range of 3rd gear or higher.
This function can be used at the following traffic condition. (It is important to be careful for using this
function)
Cruise control (ON)
Cruise control (OFF)
Cruise control (Acceleration)Cruise control (Deceleration)
Cruise control (Reset)

01-90000-00
G-sensor(4WD, ABS)
For the vehicle with the ABS, a speed difference
between the wheels is not noticeable as all the
wheels are slipping during abrupt braking.
Therefore, the vehicle needs the speed information
from other sensors other than the wheel speed
sensor. The longitudinal acceleration sensor (G-
sensor) is used for this case. It controls the ABS by
using the signals from the sensor during abrupt
braking and acceleration.
TCU unit
The transmission control unit (TCU) is installed under
the driver seat, and controls the transmission. The
TCU is operated by the ignition power supply and
receives and processes the following information from
the inner sensors through CAN buses.E-coupling unit
The E-coupling unit is a control unit which
determines the magnetic force by
considering CAN signals (wheel speed,
engine torque, pedal opening, ABS/ESP
CAN signals, etc.) from other ECUs.
TGS Lever assembly
The TGS communicates with TCU
(Transmission Control Unit), ECU,
ESP HECU and instrument cluster
to let the driver select the desired
transmission gear and to maintain
the desired driving condition. Also,
the tip switch is installed on the
lever knob and the steering wheel
so that the driver select the gear
manually when the shift lever is in
"M".Sensor cluster
The sensor cluster is linked to
the sensors on the unit board
and CAN interface. And they
are housed in one case and
mounted to the body.

01-110000-00
M6LF1 manual transmission
M6LF1 manual transmission is a model modified from the
one that used in other vehicle so that it can be applied to FF
(Front engine-Front wheel driving) type vehicle, and has an
axle in one piece. The engine torque and gear ratio of this
transmission have been optimized to maximize driving
performance. It provides 6 speeds for forward travel and 1
reverse travel.
Clutch assembly
M6LF1 manual transmission is a model modified from the
one that used in other vehicle so that it can be applied to FF
(Front engine-Front wheel driving) type vehicle, and has an
axle in one piece. The engine torque and gear ratio of this
transmission have been optimized to maximize driving
performance. It provides 6 speeds for forward travel and 1
reverse travel.
The 2WD vehicle with manual transmission is a front wheel drive type vehicle that doesn't have PTU,
propeller shaft, E-coupling and rear axle which are applied to 4WD vehicle. Its under structure is very
simple.
Manual gear selector lever
Transmission sideControl shaft assembly
Transaxle side
Concentric slave assembly
Pressure plate
2) 2WD Vehicle With Manual Transmission
Clutch disc

01-230000-00
3) General Instructions
Before lifting up the vehicle with a lift, correctly support the lifting points.
When using a jack, park the vehicle on a level ground and place the wheel chocks under the tires.
Position the jack under the frame and lift up the vehicle and then support with chassis stand before
service work.
Make sure to disconnect the negative (-) cable from the battery to prevent any damage to electric
systems.
If you have to work on vehicle, cover the seats and floor with protection covers to avoid any
damage and contamination.
Brake fluid and anti-freeze can damage the painted surface of body. So carefully handle them
during service work.
To improve the efficiency of service work, use only recommended and specified tools.
Use only Ssangyong genuine spare parts.
Never reuse the cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace them
with new ones. If reused, normal functions cannot be maintained.
Store the disassembled parts as a set based on disassembly order and unit.
Pay particular attention not to miss or mix the fasteners.
If necessary, especially for inspection, clean the removed parts completely.
Apply the oil or grease on the running and sliding surfeces before installation. Use the specified
sealant and gasket to prevent leakage if necessary.
Tighten the fasteners to the specified tightening torque.
As a final stage of service work, check if the serviced system is working properly and the problem
has been eliminated clearly. (1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14) Remove the engine and transaxle as a set.
Manual transaxle: Transaxle can be separated after removing the front module (sub frame, engine
and transaxle).
Automatic transaxle: Transaxle can be separated after removing the sub frame. -
-
2) Equipment
Korando is FF (Front Engine Front Drive) type vehicle, and engine and powertrain system are
integrated into a module. Therefore, 2-post lift and general equipment are necessary when working
on the engine and transmission.
Major equipment: Engine and transmission jack, Engine stand, Engine crane, Transmission jack,
Engine hanger -
-
Engine stand
Engine crane

02-8
1. OVERVIEW
Engine power reaches the transaxle via a torque converter with integral converter lock-up clutch. The six
forward gears and one reverse gear are obtained from a single planetary set, followed by a double
planetary set. This type of gear-set arrangement is commonly known as Lepelletier type gear-set.
The Model M11 6 speed automatic transaxle is electronically controlled. The control system is
comprised of the following components:
External transaxle control unit (TCU)
Internal embedded memory module (EMM)
Input and output speed sensors
Valve body unit comprised of four ON/OFF solenoid valves and six variable bleed solenoids (VBS)
Torque converter -
-
-
-
-
TCU controls the oil pressure for various internal clutches and bands to select the gear. It also controls
the electronic elements, shift pressure and torque converter slip. If the system is defective, TCU provides
FMEC (Failure Mode Effect Control) to maintain the functionality of transaxle. This keeps the basic
function of transaxle (gear selection) even when there are failure in controls and power supply.
There are selector shaft position sensor (inhibitor switch) and oil temperature sensor in transaxle. In
manual mode, TCU receives the information from TGS (Transmission Gear Selector) through PCB
(Printed Circuit Board) when driver selects the manual shift mode. TCU communicates with other
electric control modules through CAN. In order to ensure a safe driving state and to prevent damage to
the automatic transmission, TCU switches to Limp-Home mode in the event of critical faults.

02-16
3) Shift Map Selection
The driver can manually select between normal (S) and winter modes (W) via the mode switch.
Depending on the transaxle temperature, uphill and downhill grades and altitude, shift maps will be
selected by the TCU to suit the driving conditions. The following maps are available.
Standard (Normal) Mode ▶
Normal Mode is selected when the lever is in the D position with the mode switch in the normal (S)
position and the transaxle is within normal temperature ranges. Shift schedule points are optimised for
fuel efficiency and general driving conditions.
Uphill and Downhill Mode ▶
In this mode, depending on the load of the vehicle, adaptive shift maps are selected to progressively
adjust the shift points and torque converter lock points.
Altitude Mode ▶
Shift points are automatically adjusted at higher altitudes to compensate for changes in engine torque
where the torque produced by the engine is greatly reduced by the effects of reduced barometric
pressure and temperature.
Winter (W) Mode ▶
When winter mode is selected, starting in second gear is facilitated and the WINTER mode indicator
light is switched ON. To prevent wheel spin on slippery surfaces, the transmission will not allow first gear
unless manually overridden.
Warm up Schedule ▶
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470089008c00930096009e00470059005700b6006a0055>
The torque converter will not lock-up below 20°C to assist in transaxle warm-up.
Hot Mode ▶
<007b008f008c0047008f0096009b004700940096008b008c00470090009a0047009700990096008e0099008c009a009a0090009d008c009300a0004700880097009700930090008c008b00470089008c009b009e008c008c00950047009b008c0094009700
8c00990088009b009c0099008c009a00470096008d00470058>10° ~ 200°C. The torque
converter lock-up is increased to prevent heat generation by the torque converter.
Activation of the hot mode inhibits other transmission performance features including uphill and downhill
compensation and altitude compensation. Some degradation in shift feel may be experienced as the
torque converter is not unlocked during shifting.
Cruise Control Mode ▶
When cruise control is activated the engine ECU may request the transaxle to downshift under trailing
throttle conditions to increase engine braking.
Above 110℃the electrical radiator fans are switch ON
Above 130℃the engine torque will be reduced and the W light on the instrument cluster will flash
Above 200℃the transaxle will neutralise until the fluid tem
perature falls below 200°C as a final
protection.

03-113660-01
1. OVERVIEW
2WD4WD
The Model 6F24 6 speed automatic transaxle is electronically controlled. The control system is
comprised of the following components:
External transaxle control unit (TCU)
Input and output speed sensors
Six variable force solenoids(VFS) and two on/off solenoids
Torque converter
ATF temperature sensor -
-
-
-
-
TCU controls the oil pressure for various internal clutches and brakes to select the gear. It also controls
the electronic elements, shift pressure and torque converter slip. If the system is defective, TCU provides
FMEC (Failure Mode Effect Control) to maintain the functionality of transaxle. This keeps the basic
function of transaxle (gear selection) even when there are failure in controls and power supply.
There are selector shaft position sensor (inhibitor switch) and oil temperature sensor in transaxle. In
manual mode, TCU receives the information from TGS (Transmission Gear Selector) through PCB
(Printed Circuit Board) when driver selects the manual shift mode. TCU communicates with other electric
control modules through CAN. In order to ensure a safe driving state and to prevent damage to the
automatic transmission, TCU switches to Limp-Home mode in the event of critical faults.