transmission fluid SSANGYONG MUSSO 1998 Workshop Owner's Manual

AUTOMATIC TRANSMISSION 5A-103
11. Assemble the piston return spring to the piston, and fit the
spring retainer over the spring.
Notice
The wire diameter of this spring is 4.3 mm.
12. Using special tool No. 0555-331899, compress the spring
sufficiently to enable the installation of the retaining circlip
ensuring that the circlip is firmly seated in its groove, then
remove the tool.
13. Check the C1 piston check valves are not damaged and
are free to move, and that the cylinder feed orifices are
clear of obstructions.
14. Lubricate the’0’rings with automatic transmission fluid and
fit them to their respective grooves.
Notice
‘O’ rings must not be twisted in the grooves.
15. Position the cylinder with the C1 cavity upwards. Install the
piston into the cylinder until the outer diameter of the piston
enters the inner diameter of the cylinder.
16. Install the spring and spring retainer onto the piston.
Notice
The wire diameter of this spring is 5.26 mm.
17. Using special tool No. 0555-331899, compress the spring
sufficiently to enable the installation of the retaining circlip
ensuring that the circlip is firmly seated in its groove, then
remove the tool.
18. Install the C2 wave washer into the cylinder with the crest
of one wave covering one of the bleed orifices in the C2
piston.
19. Measure and record the thickness of the flange of the C2
sleeve. Refer to figure 8.25.
20. Install the C4 clutch plates and wave washer into the C2
actuating sleeve, with the rounded edge of the steel plates
down, in the following sequence:
lSteel plate (selective)
lFriction disc
lSteel plate
lFriction disc
lSteel plate
lFriction disc
lSteel plate
lWave washer

AUTOMATIC TRANSMISSION 5A-105
21. Holding the cylinder horizontal, install the sleeve and clutch
plate assembly into the cylinder, with the crest of one wave
of the washer In line with one of the holes in the outside of
the cylinder, until the sleeve contacts the C2 wave washer.
22. Check the C4 clutch pack clearance using special tool No.
0555-331900. Refer to figure 8.25.
Notice
With the C2 wave spring compressed, and the clutch Pack
supporting a 2 k9 weight, the dimension from the underside
of the C2 pressure plate to the selective steel is to be
between 1.4- 1.8 mm. If the clutch is to be gauged from
the top of the pressure plate, then the dimension is to be
the actual thickness of the pressure plate plus 1.4-1.8 mm.
23. Use selective plates to achieve the correct specification. If
new friction plates are being fitted, remove the clutch pack
and soak the friction plates in ATF for a minimum of 5
minutes prior to reassembly.
Notice
The clutch pack clearance must be taken before the
elements are soaked in Automatic Transmission Fluid
(ATF).
24. Reassemble the sleeve and clutch pack into the cylinder.
Observe the alignment of the wave washer to the hole in
the cylinder.
25. Install the C2 clutch plates in the cylinder in the following
sequence:
lFriction disc
lSteel plate
lFriction disc
lSteel plate
lSteel plate - 0574-000001, 0574-000003,
0574-000004, 0574-000005, 0574-000020,
0574-000021, or friction disc -0574-000002
lSteel plate (selective)
lFriction disc
lSteel plate (selective)
lFriction disc

AUTOMATIC TRANSMISSION 5A-107
C3 Clutch and Reverse Sun Gear Assembly
To assemble the C3 clutch and reverse sun gear assembly
(refer to figure 8.28), proceed as follows.
1. Check the orifices in the cylinder are clear of obstructions.
2. Check the C3 cylinder bush outside diameter and the
centre support inside diameter are in good condition and
not damaged. Coat the sealing rings with automatic
transmission fluid and fit into the C3 cylinder grooves.
3. Check the reverse sun gear splines, grooves and thrust
face for condition. Coat the ‘O’ ring with automatic
transmission fluid and fit it to the groove of the reverse
sun gear.
4. Install the reverse sun gear in the C3 cylinder, ensuring
that the ‘O’ ring compression is adequate but not
excessive.
Notice
‘O’ rings must not be twisted in the grooves.
5. Coat the C3 piston ‘O’ rings with automatic transmission
fluid and fat the small ‘O’ ring onto the inner ring and the
large ‘O’ ring onto the outer ring of the C3 piston.
6. Check that the bleed orifices of the piston are clean and
clear of obstructions.
7. Install the C3 piston in the cylinder until the outside
diameter of the piston enters the inside diameter of the
cylinder.
Notice
Take care not to cut the ‘O’ ring.
8. Assemble the spring and spring retainer on the piston.
Using tool No. 0555-331899 compress the spring
sufficiently to enable the installation of the retaining circlip,
ensuring that the circlip is firmly seated in the groove, and
remove the tool.
9. Fit the C3 wave plate to the C3 piston face, ensuring that
one crest of the wave plate of the C3 piston face is aligned
over one of the piston orifices.
10. Assemble the clutch plates and discs into the cylinder in
the following sequence :
lSteel plate
lFriction disc
lSteel plate
lSteel plate - 0574-000001, 0574-000003,
0574-000004,0574-000005,0574-000020,
0574-000021, or friction disc -0574-000002
lSteel plate (selective)
lFriction disc
lSteel plate (selective)
lFriction disc
11. Align and fit the pressure plate with the counterbore facing
away from the clutch plates.Figure 8.28 - C3 Clutch and Reverse Sun Gear

5A-108 AUTOMATIC TRANSMISSION
12. Install the circlip.
13. Check the C3 clutch clearance (refer to figure 8.29) using
special tool No.0555-331900 in the following manner
(weight only).
a. Place the weight on the pressure plate and measure
the distance from the end of the cylinder to the top of
the pressure plate.
b. Record this figure.
c. Remove the weight.
d. Lift the pressure plate up against the circlip and
measure the distance from the end of
the cylinder to the top of the pressure plate.
e. Record this figure.
f. Subtract the second reading from the first reading to
obtain the clutch pack clearance.
Notice
With the clutch pack supporting a weight of 2 kg, the
clearance between the snap ring and the top of the
pressure plate is to be between 1.20-1.45 mm.
14. If new friction plates are being fitted, remove the clutch
pack and soak the friction elements in automatic
transmission fluid for a minimum of five minutes prior to
reassembly.
Notice
The clutch pack clearance must be taken before the
elements are soaked in automatic transmission fluid.Figure 8.29 - Typical C3 Clutch Assembly
Clearance

5A-110 AUTOMATIC TRANSMISSION
C1 Clutch Overdrive Shaft and Input Shaft
Assembly
Notice
1. Ensure that the snap rings are fitted correctly.
2. Check pistons for cracks, especially the C1 piston.
3. Do not mix clutch piston return springs.
4. 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.
To assemble the C1 clutch overdrive shaft and input shaft
assembly, proceed as follows:
1. Check the overdrive shaft grooves for any defect.
2. Coat the sealing rings, large and small, with petroleum 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:
lsteel plate
lfriction disc
lsteel plate
lfriction disc
lsteel plate
lsteel plate - 0574-GOOGOl, 0574-000003,
0574-000004, 0574-000005, 0574-000020,
0574-000021, or friction disc -0574-000002
lsteel plate (selective)
lfriction disc
lsteel plate (selective)
lfriction disc
4. Check the clutch pack clearance using special tool No.0555-
331900. Refer to figure 8.31.
Use selective plates to achieve the correct specification.
Notice
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.
5. If new friction plates are being fitted, remove the clutch pack
and soak the friction elements in automatic 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.
6. Check the fit of the C1 clutch hub on the overdrive shaft. If
it is loose, the hub and shaft assembly must be replaced.Figure 8.31 - Typical C1 Clutch Assembly
Clearance

5A-112 AUTOMATIC TRANSMISSION
Pump Cover and Converter Support
Notice
1. Do not wash the nose of solenoids in solvent.
2. Ensure that the correct ‘O’ ring is fitted for the application.
3. Do not mix up the low first blow-off and the torque converter
blow-off ball springs.
4. Be careful not to damage the needle bearings on the
assembly. Avoid any axial impact loads during assembly.
5. Check the transmission end float. This will help to detect
any missing parts or incorrect assembly.
Notice
Figure 8.35 shows the orientation of the cross- sections for
figures 8.36 to 8.42.
To assemble the pump cover and converter support
(refer to figures 8.34 and 8.35), proceed as follows.
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.Figure 8.34 - Pump, Cover and Converter
Support
Figure 8.35 - Pump Cover Assembly

5A-126 AUTOMATIC TRANSMISSION
Oil Filter and Pan Assembly
Notice
1. Replace the filter whenever rebuilding a transmission where a significant amount of mechanical damage has
occurred.
2. 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.
3. Ensure that the internal line pressure plus in the valve body is fitted.
To assemble the oil filter and pan assembly (refer to figures 8.63 and 8.64), proceed as follows.
1. Lubricate the oil filter sealing ring with automatic transmission fluid.
2. Carefully assemble the oil filter to the valve body. The spigot must not lean on one side while being fitted. Refer to
figure 8.63.
3. Secure the oil falter assembly with the retainer.
4. Check that the magnet is located in the dimple in the comer of the oil pan.
5. Assemble the gasket on the pan lip. The gasket must be free of any distortion when installed.
6. Fit the oil pan assembly to the transmission case and tighten the securing bolts to specification and sequence
(refer to figure 8.65). Do not over torque.

TRANSFER CASE (TOD) 5D2-47
Assembly Procedure
Assembly
Before assembly, lubricate all parts with Automatic Transmission
Fluid or equivalent.
1. If removed, drive the bearing into the front output case bore.
Drive the bearing in staight, making sure it is not cocked in
the bore. Install the internal snap ring that retains the bearing
to the front case.
2. If removed, install the front yoke to flange seal in the front
case bore.
3. If removed, install the yoke to flange seal into the mounting
adapter bore.
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Thrust Washer
8 Bearing
9 External Snap Ring
10 Internal Snap Ring
4. If the input shaft needle bearing and bushing were removed,
install a new bearing and bushing as detailed in the following
steps:
Press a new needle bearing, then a new bushing in the
input shaft as follows:
a. Position the input shaft on Axle Bearing/Seal Plate or
equivalent, and Pinion Bearing Cone Replacer as a
spacer.
b. Press a new needle bearing into the end of the input
shaft until it seats in the input shaft.
c. Press in a new bushing.
5. The recessed face of the sun gear and the snap ring groove
on the bearing outer race should be toward the rear of the
transfer case. The stepped face of the thrust washer should
face toward the bearing.
Slide the sun gear, thrust plate and thrust washer into
position on the input shaft. Press the bearing over the input
shaft. Install the external snap ring to the input shaft.

5D2-48 TRANSFER CASE (TOD)
6. Install the front planet to the sun gear and input shaft.
Install the internal snap ring to the planetary carrier.
7. Place the tanged snap ring in the case. Expand snap ring
with snap ring pliers and install planetary carrier assembly.
Check installation by holding the case and carefully tapping
the face of the input shaft against a wooden block to make
sure the snap ring is installed.
8. Remove all traces of gasket sealant from the front case
and mounting adapter mating surfaces. Install a bead of
gasket sealant on the surface of the front case.
9. Install the high-low shift fork and high-low collar as an
assembly into the front planet.
Notice
Make sure that the nylon wear pads are installed on the
shift fork and snapped securely into place.
12 Rear Output Shaft
13 Oil Strainer
14 Coupling Hose
15 Hose Clamp
16 Pump Body
10. If new pump is used, align the flat of the output shaft and
the flat of the pump. Slide the pump onto the output shaft.
lDo not disassemble oil pump. It is serviced only as an
assembly. Check the pump to make sure the pump
rotates freely.
lDo not remove the plastic insert from the bore of the
new pump. Discard it after it slides out during pump
installation to the rear output shaft.
lWhile turning the output shaft, prime the pump through
the oil filter pickup tube or housing inlet hole with clean
Automatic Transmission Fluid or equivalent.
11. Inspect the outside surfaces and bore of the oil pump. If
there is no discoloration in the pump housing, gear or cover,
and the pump bore and the lube holes of the output shaft
show evidence of oil, the pump is working.

TRANSFER CASE (TOD) 5D2-53
40. Install the rear case flange on the output shaft. Install the
rubber seal, output shaft yoke washer and nut. Tighten
the nut.
Tightening Torque 137 - 196 Nm
41. Install the drainplug and tighten.
42. Fill the transfer case with 1.4 liters of Automatic
Transmission Fluid or equivalent.
Notice
Fluid level should be just below the filler plug hole.
Tightening Torque 19 - 30 Nm
Tightening Torque 19 - 30 Nm 43. Install the fill pulg and tighten.
44. Install the transfer case as outlined in removal and
Installation, transfer case in the section.
Notice
Make sure proper drain and fill plugs are installed if case
is replaced.