torque SSANGYONG MUSSO 1998 Workshop Repair Manual

AUTOMATIC TRANSMISSION 5A-83
Tightening Torque 70 - 80 Nm
11. Remove the two pipes for oil cooler.
Installation Notice
Tightening Torque24.5 - 34.3 Nm
12. Remove the service hall cover on torque converter.
13. Put the alignment mark for installation, and unscrew the
six mounting bolts for torque converter from drive plate
through the service hole (arrow) by rotating the engine
and remove the torque converter.
Installation Notice
Tightening Torque 42 Nm
7. Remove the rear propeller shaft.
Installation Notice
8. Unscrew the five bolts and remove the transfer case.
9. Disconnect the 10-Pins Plug connector from transmission.
10. Separate the locking clip on shift lever and remove the
shift rod.
Notice
Removal and installation performed when the shift
procedure should be lever is in “D” range.
Screw the six bolts mounting the torque converter through
the service hole by using a mirror and rotating the engine.

5A-84 AUTOMATIC TRANSMISSION
Tightening Torque 55 - 65 Nm
14. Remover the starter.
15. Unscrew the eight transmission housing 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.

5A-94 AUTOMATIC TRANSMISSION
ASSEMBLY PROCEDURE
The transmission is assembled in modular fashion and details
of assembly for each module are given under the appropriate
subject. Refer to table 8.1 (at the end of Section 8.3) for the
torque specifications to be applied, and to table 9.10 in section
9.6 for details of all special tools required, when performing
assembly procedures. Technicians overhauling these
transmissions will also require a selection of good quality Torx
bit sockets, in particular numbers 30,40 and 50, and an 8 mm,10
mm and 12 mm double hex socket.
Transmission
Notice
1. Ensure that the B1R circlip is fitted to the case. (If this is not
fitted, the valve will peen its way into and through the
separator plate.)
2. Ensure that the ‘E’ clip is fitted to the cross shaft.
3. Ensure that all aspects of the parking mechanism are
working.
To assemble the transmission, proceed as follows:
1. Turn the transmission case upside down on the bench and
mount it to the transmission cradle No.0555-331895.
2. Install all fittings, plugs and the breather, applying a sealant
where applicable, Tighten the fittings to specifications.
Ensure that the breather is clear, and check that the lube
fitting in the rear of the case is fitted and clear of obstruction.
3. Assemble the B1R valve and spring, and secure with the
irclip. Refer to Ensure that the circlip is completely seated
in its groove.
4. Install the rear servo lever and pivot pin.
Notice
The lever must pivot freely on its pin.

5A-96 AUTOMATIC TRANSMISSION
9. Check that the cam collar slides freely on the rod.
10. Insert the cross shaft into the case, from the side opposite
to the inhibitor switch, then install the anti-rattle spring on
the shaft.
11. Position the manual valve detent lever, aligning it with the
cross-shaft bore in the case.
12. Push the shaft through the detent lever until it starts in the
detent lever side of the case.
13. Install the detent lever drive pin in the shaft using tool No.
0555-331897 with the adaptor over the pin.
14. Press the pin into the shaft until the tool bottoms.
15. Remove the tool and fit the spring retaining circlip to the
shaft.
16. Install the new cross shaft seals using tool No. 0555-
331894.
17. Install the inhibitor switch on the case. Torque the screws
as per specifications. Press the pin into the shaft until the
tool bottoms (4WD models) using tool No.0555-332942.
18. Thoroughly check the terminal wiring loom for condition
and continuity.
19. Position the loom and locate the solenoid 7 contact and
terminal in the pump mounting flange at the front of the
case. The solenoid 7 wire is routed under the park rod
and cross shaft in the case.

5A-100 AUTOMATIC TRANSMISSION
Planet Carrier Assembly and Centre Support
To assemble the planet carrier assembly and centre support,
proceed as follows.
1. Check the carrier and planet assembly for any damage or
irregularity and ensure that all pinions rotate freely and
that the pinion end float is within the tolerance stated in
section 9.2.
2. Install the one way clutch (OWC) retainer to the planet
carrier with the inner edge pointing downwards. Inspect
the OWC race and the sprag assembly for wear or damage.
Replace if necessary.
3. Install the outer race in the drum. Press the race to the
bottom of the drum and install the retaining circlip. Ensure
the circlip is firmly seated in its groove.
Refer to figure 8.21.
4. Install the OWC into the outer race with the lip edge
uppermost. Lubricate the sprags with automatic
transmission fluid. Refer to figure 8.20.
5. Check that the plugs are fitted to the centre support, then
assemble the centre support into the OWC, ensuring that
the support will rotate in an anti-clockwise direction only.
Refer to figure 8.21.
Figure 8.20 - Planet Carrier Assembly and
Centre Support
6. Lubricate the No.9 needle thrust bearing and the thrust
washer with petroleum jelly and fit them to the rear face of
the planet carrier. Refer to figure 8.19.
7. Install the planet assembly and the centre support into the
case, and align the centre support mounting bolt holes.
8. Install the centre support bolts finger tight.
9. Install the circlip retainer ensuring that the circlip is
completely seated in the groove of the case.
10. Remove the centre support bolts and apply Loctite 222 or
equivalent to the threads. Install the bolts and torque to
specifications.

AUTOMATIC TRANSMISSION 5A-101
Extension Housing Assembly
To assemble the extension housing assembly, proceed as
follows.
1. Check the condition of the extension housing roller bearing.
Replace if necessary (RWD models). Install the new bearing
from rear of extension housing. Press on the branded face
of bearing only.
2. Install a new seal to the extension housing or adaptor
housing. Refer to figure 8.21.
Notice
Do not use petroleum jelly to hold the gasket in position.
3. Position a new gasket onto the extension housing or adaptor
housing.
Notice
See section 8.3.17 for the procedure to assemble the output
flange assembly - RWD models.
4. Install the extension housing (RWD) or adaptor housing
(4WD) and torque the bolts to specification.
Front Servo Assembly
NOTICE
Ensure that the front servo snap ring is installed correctly.
Orient the circlip with the gap at the bottom, near the pan rail.
Refer to figure 8.22.
To assemble the front servo assembly (refer to figure 8.22),
proceed as follows.
1. Lubricate the cover ‘O’ ring with automatic transmission fluid
and fit to the cover.
2. Lubricate the piston ‘O’ rings with automatic transmission
fluid and fit to the piston.
3. Assemble the piston, push rod, spring, belleville washer,
seat and retaining ring.
4. Fit the piston push rod assembly into the front servo cover.
5. Install the front servo block and spring into the case.
6. Install the front servo assembly into the case.
7. Compress the servo cover and fit the servo cover retaining
circlip, aligning the gap with the pan rail, and ensuring that
it is completely seated in its groove.
Figure 8.21 - Extension Housing
Figure 8.22 - Front Servo and Band

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-118 AUTOMATIC TRANSMISSION
Valve Bodies
Notice
1. Do not wash the nose of solenoids in solvent.
2. Be aware of ball positions in the upper valve body.
3. Be aware of 1-2 and 3-4 shift valve positions, they can be
swapped.
4. Check the 4-3 sequence valve and spring orientation.
5. Check that the 12 mm ball is in the lower body.
6. Do not mix up the low first blow-off and the torque converter
blow-off ball springs.
7. Check the line pressure relief valve for swarf, and be aware
of replacing the shims.
8. The orifices in the valve body are for stability and safeguard;
do not drill them any larger.
9. When servicing the transmission, ensure that the solenoid
5 damper spring is not broken.
10. Locate the detent spring central to the detent lever.
To assemble the valve bodies, proceed as follows.
1. Wash the upper and lower valve bodies (refer to figures
8.47 and 8.48) thoroughly with cleansing solvent and blow
dry.
2. Check the valve body cavities, ports and holes for damage
or obstructions.
3. Install the detent lever locating pin.
4. Thoroughly wash all loose components.
5. Check that all valves slide freely in their location.
Figure 8.47 - Lower Valve Body
Figure8.48 - Upper Valve Body Showing Check
Ball Locations

AUTOMATIC TRANSMISSION 5A-125
30. 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. Refer to figure 8.61.
31. Check the alignment of the detent roller and the manual
lever quadrant.
32. Connect the solenoid wiring as detailed below:
lSolenoid 1 - red
lSolenoid 2 - bIue
lSolenoid 3 - yellow
lSolenoid 4 - orange
lSolenoid 5 - green
lSolenoid 6 - violet (Refer to figure 8.62.)
Notice
All hardware must be correctly installed and torqued to
specification.
Figure 8.61 - Tightening Sequence Valve Body to Case

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.