engine SSANGYONG MUSSO 1998 Workshop Repair Manual

AUTOMATIC TRANSMISSION 5A-79
ADJUSTMENTS
HYDRAULIC SYSTEM
The procedures detailed below should be followed in the event that the self test procedure detailed in section 6, or a
defect symptom, indicates that there is a fault in the hydraulic system.
When making adjustments to the transmission, select the appropriate procedures from the following preliminary
checks.
lConduct a transmission fluid test procedure, refer to section 7.2.
lCheck the manual linkage adjustment (refer to the vehicle workshop manual).
lCheck engine idle speed (refer to Section 7.3).
lConduct a stall test (it is outside the scope of this publication to detail this procedure)
lconduct a road test (it is outside the scope of this publication to detail this procedure).
TRANSMISSION FLUID TEST PROCEDURE
Checking Transmission Fluid Level
This procedure is to be used when checking a concern with the fluid level in a vehicle. A low fluid level will result in
gearshift loss or delay if driven when the vehicle is cold.
The vehicle is first checked for transmission diagnostic messages (refer to section 6). If the vehicle has a speedo fault
it is possible for the oil level to be low.
The vehicle is to be test driven to determine if there is an abnormal delay when selecting drive or reverse, or loss of
drive. One symptom of low oil level is a momentary loss of drive when driving the vehicle around a comer. Also when
the transmission fluid level is low, a loss of drive may occur when the transmission oil temperature is low.
If there is no loss of drive when the vehicle is driven warm and a speedo fault is registered, then fluid should be added
to the transmission.
Checking, Adding Fluid and Filling
When adding or changing transmission oil use only Castrol TQ 95 automatic transmission fluid (ATF) or other approved
fluids. The use of incorrect oil will cause the performance and durability of the transmission to be severely degraded.
Do not underfill the transmission. Incorrect tilling may cause damage to the transmission. The fluid level setting
procedure is detailed below.
Notice
When a transmission is at operating temperature hot transmission fluid may come out of the case if the fill plug is
removed. 9 the transmission is at operating temperature allow two hours for cooling prior to removing the plug.
1. If the vehicle is at operating temperature allow the vehicle to cool down for two, but no greater than four hours
before adding transmission fluid (this will allow the transmission to be within the correct temperature
range).
While hot the ATF level is higher and removing the plug may result in oil being expelled from the filler hole. This
will result in the level being low.
2. The transmission selector is to be in Park.
Switch the engine off.
3. Raise the vehicle on a hoist (or leave over a service pit).
4. Clean all dirt from around the service fill plug prior to removing the plug. Remove the oil service fill plug.
Clean the fill plug and check that there is no damage to the ‘O’ ring.
Install the filler pump into the filler hole.
5. Lower the vehicle with the filler pump still connected and partially fill the transmission.
Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission
gear selector through all positions, adding ATF until gear application is felt.

5A-80 AUTOMATIC TRANSMISSION
6. Switch off the engine and raise the vehicle on the hoist, if applicable, ensuring that the vehicle is level.
7. Three minutes after the engine has stopped, but no longer than one hour, remove the filler pump, The correct
level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATF to the correct level.
8. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle.
9. Tighten the transmission filler plug to specification.
Checking, Adding Fluid and Filling - Drained or Dry Transmission
To set the correct fluid level proceed as follows.
1. Set the transmission selector to Park and switch the engine off.
2. Raise the vehicle on a hoist (or leave over a service pit).
3. Clean all dirt from around the service fill plug prior to removing the plug, Remove the oil service fill plug. Clean the
fill plug and check that there is no damage to the ‘O’ ring. Install the filler pump into the filler hole.
4. Lower the vehicle with the filler pump still connected and partially fill the transmission. This typically requires
approximately :
a. If the transmission torque converter is empty:
9.0 litres - 4WD
9.0 litres - RWD
b. If the transmission torque converter is full:
4.5 litres - 4WD
4.5 litres - RWD
5. Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission
gear selector through all positions, adding ATF until gear application is felt.
6. Then add an additional 0.5 litres of ATF.
7. Switch off the engine and raise the vehicle on the hoist. Remove the filler pump and replace the filler plug. The
plug shall be tightened to specification.
8. The vehicle is then to be driven between 3.5 and 4.5 kilometers at light throttle so that the engine does not
exceed 2500 rpm. This should result in the transmission temperature being in the range 50 to 60°C.
9. With the engine idling, cycle the transmission selector through all gear positions with the brake applied.
10. Stop the engine. Raise the vehicle on the hoist, if applicable ensuring the vehicle is level.
11. Three minutes after the engine has stopped, but no longer than one hour, remove the filler plug. The correct
level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATP to the correct level.
12. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle. Tighten the
transmission Filler plug to specification.
ELECTRONIC ADJUSTMENTS
Idle Speed Adjustment
Carry out the adjustments to the idle speed as detailed in the workshop manual.
Throttle Position Calibration
Should the throttle position data stored in the TCU be lost or be out of specification, as indicated by a diagnostic
trouble message, it may be re-established by the following procedure.
lCheck that the hot engine idle speed is within specification.
lAllow the engine to idle in ‘Drive’ for 60 seconds with the air conditioner (if fitted) turned off. The closed throttle
reference point in the TCU has now been set.
Switch the engine off but leave the ignition on. Hold the accelerator pedal on the floor for 60 seconds. The wide open
throttle reference point in the TCU has now been set.

AUTOMATIC TRANSMISSION 5A-81
Throttle Clearing
The leant throttle clearing routine uses the mode switch and gear lever. Carry out the following steps to complete the
automated throttle clearing procedure:
1. Switch ignition ‘ON’ with handbrake applied and engine ‘OFF’.
2. Select ‘M1’ and ‘WINTER’ mode.
3. Move the T-bar to ‘M2’ and then select ‘NORMAL’ or ‘POWER’ mode.
4. Move the T-bar to ‘M3’ and then select ‘WINTER’ mode.
Vehicle Coding
The vehicle coding is integrated as part of the diagnostic software. The coding applies to the following vehicle
models:
1. 4WD Gasoline E32.
2. 4WD Gasoline 523
3. 4WD Gasoline 520.
4. 4WD Diesel D29NA.
5. 4WD Diesel D29LA.
6. 4WD Diesel D23LA.
7. RWD E20.
8. RWD E23.

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.

MANUAL TRANSMISSION 5B-5
Check
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.Check
Control lever assembly broken or damaged.
Damaged offset lever, shift fork, selector place or
selector arm.
DIAGNOSIS
WILL NOT SHIFT(CONTROL LEVER MOVES)
Action
Replace control lever and housing assembly.
Remove extension, adapter or case cover.
Check or replace damaged parts.
HARD SHIFT OR CONTROL LEVER WILL NOT MOVE INTO GEAR
Action
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.
GEARS CRASH WHEN SHIFTING
Check
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.Action
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.

5B-6 MANUAL TRANSMISSION
Check
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.
TRANSMISSION JUMPS OUT
Action
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.
Check
Fork or offset lever loose on shaft or rail.
Worn or damaged forks, offset lever, shaft or rail.
Worn or damaged synchronizer.
Worn or damaged gears.
TRANSMISSION LOCKED IN ONE GEAR
Action
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 worn or damaged synchronizer parts and
replace if necessary.
Check worn or damaged gears and replace if neces-
sary.
Check
Improper or low transmission oil.
Loose bolts or other attaching parts.
Improper flywheel housing to engine crankshaft
alignment.
Noisy transmission bearing.
Noisy gears.
TRANSMISSION NOISE
Action
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 necessary.
Check for worn or damaged gears
(including speedometer gear).
Replace if necessary.

5B-16 MANUAL TRANSMISSION
7. Remove the front and rear propeller shafts from the
transfercase.
Installation Notice
Tightening Torque81 - 89 Nm
70 - 90 NmFront
Rear
8. Support the transmission on an suitable jack.
Unscrew the center mounting nuts and each sides
mounting bolts and remove the cross member.
Installation Notice
9. Remove the transmission mounting bolts.
Installation Notice
Tightening Torque (1)
Tightening Torque (2)21 - 35 Nm
62 - 93 Nm
10. Move the transmission jack backward careful and
disengage the transmission input shaft from the engine.
Remove the transmission.
11. Installation should follow the removal procedure in the
reverse order.
Tightening Torque 77 - 87 Nm

5B-46 MANUAL TRANSMISSION
lCheck 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 :
lPressure plate spring assembly
lDisc
lFlywheel
lInput shaft pilot bearing
Notice
Replace the excessively worn parts.
6. Lubricate the clutch release bearing bore, fork pivot head
during assembly.

CLUTCH 5C-3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
602 589 00 40 00
Engine Lock661 589 00 15 00
Centering Pin

5C-4 CLUTCH
Checks
Oily Facing
Hard or Faulty Facing
Burnt Torsion Spring
Faulty Pressure Plate
Bent Clutch Diaphragm Spring
Hard or Bent Flywheel
Engine Mounts Loose or Burnt LeverAction
Adjust Pedal Freeplay
Repair Release Cylinder
Repair or Replace
Repair as Necessary
Replace Checks
Excessive Clutch Pedal Free play
Faulty Clutch Release Cylinder
Worn Disc, Excessive Run-out, Damaged Lining
Dirty or Burred Splines on Input Shaft or Clutch Disc
Damaged Clutch Pressure PlateChecks
Vibration or Excessive Run-out of Disc
Rust or Wear of Disc Spline
Oily Facing
Damaged Diaphragm Spring
Excessive Clutch Pedal Free play
DIAGNOSIS
CLUTCH SLIPS
Checks
Excessive Wear of Facing
Hard or Oily Facing
Damaged Pressure Plate or Flywheel
Damaged or Burnt Diaphragm Spring
Clutch Pedal Free play Insufficient
Faulty Operation of Clutch Pedal
Worn or Damaged Clutch DiscAction
Replace
Repair or Replace
Replace
Replace
Adjust
Repair or Replace
Replace
POOR DISENGAGEMENT
Action
Replace
Repair or Replace
Repair or Replace
Replace
Adjust
HARD TO SHIFT OR WILL NOT SHIFT
CLUTCH CHATTERS WHEN STARTING
Action
Repair or Replace
Replace
Replace
Replace
Replace
Repair or Replace
Tighten or Replace