washer fluid SSANGYONG MUSSO 1998 Workshop Repair Manual

0B-12 GENERAL INFORMATION
OWNER INSPECTIONS
AND SERVICES
WHILE OPERATING THE VEHICLE
Horn Operation
Blow the horn occasionally to make sure it works. Check
all the button locations.
Brake System Operation
Be alert for abnormal sounds, increased brake pedal
travel or repeated puling to one side when braking. Also,
if the brake warning light goes on, or flashes, something
may be wrong with part of the brake system.
Exhaust System Operation
Be alert to any changes in the sound of the system or
the smell of the fumes. These are signs that the system
may be leaking or overheating. Have the system
inspected and repaired immediately.
Tires, Wheels and Alignment Operation
Be alert to any vibration of the steering wheel or the
seats at normal highway speeds. This may mean a wheel
needs to be balanced. Also, a pull right or left on a
straight, level road may show the need for a tire pressure
adjustment or a wheel alignment.
Steering System Operation
Be alert to changes in the steering action. An inspection
is needed when the steering wheel is hard to turn or
has too much free play, or is unusual sounds are noticed
when turning or parking.
Headlight Aim
Take note of the light pattern occasionally. Adjust the
headlights if the beams seem improperly aimed.
AT EACH FUEL FILL
A fluid loss in any (except windshield washer) system
may indicate a problem. Have the system inspected and
repaired immediately.
Engine Oil Level
Check the oil level and add oil if necessary. The best
time to check the engine oil level is when the oil is warm.
1. After stopping the engine, wait a few minutes for the
oil to drain back to the oil pan.
2. Pull out the oil level indicator (dip stick).
3. Wipe it clean, and push the oil level indicator back
down all the way.
4. Pull out the oil level indicator and look at the oil level
on it.5. Add oil, if needed, to keep the oil level above the
lower mark. Avoid overfilling the engine, since this
may cause engine damage.
6. Push the indicator all the way back down into the
engine after taking the reading.
If you check the oil level when the oil is cold, do not run
the engine first. The cold oil will not drain back to the
pan fast enough to give a true oil level reading.
Engine Coolant Level and Condition
Check the coolant level in the coolant reservoir tank
and add coolant if necessary. Inspect the coolant.
Replace dirty or rusty coolant.
Windshield Washer Fluid Level
Check the washer fluid level in the reservoir. Add fluid if
necessary.
AT LEAST TWICE A MONTH
Tire And Wheel Inspection and Pressure
Check
Check the tire for abnormal wear or damage. Also check
for damaged wheels. Check the tire pressure when the
tires are cold ( check the spare also, unless it is a
stowaway). Maintain the recommended pressures. Refer
to “Tire and Wheel” is in section 0B.
AT LEAST MONTHLY
Light Operation
Check the operation of the license plate light, the
headlights (including the high beams), the parking lights,
the fog lights, the taillight, the brake lights, the turn
signals, the backup lights and the hazard warning flasher.
Fluid Leak Check
Periodically inspect the surface beneath the vehicle for
water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air
conditioning system after use is normal. If you notice
fuel leaks or fumes, find the cause and correct it at once.
AT LEAST TWICE A YEAR
Power Steering System Reservoir Level
Check the power steering fluid level. Keep the power
steering fluid at the proper level. Refer to
Section 6A,
Power Steering System.
Brake Master Cylinder Reservoir Level
Check the fluid and keep it at the proper level. A low
fluid level can indicate worn disc brake pads which may
need to be serviced. Check the breather hole in the
reservoir cover to be free from dirt and check for an
open passage.

GENERAL INFORMATION 0B-15
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL REPAIR INSTRUCTIONS
lIf a floor jack is used, the following precautions are
recommended.
lPark the vehicle on level ground, “block” the front or
rear wheels, set the jack against the frame, raise the
vehicle and support it with chassis stands and then
perform the service operation.
lBefore performing the service operation, disconnect
the negative battery cable in order to reduce the
chance of cable damaged and burning due to short-
cir cuiting.
lUse a cover on the body, the seats and the floor to
protect them against damage and contamination.
lHandle brake fluid and antifreeze solution with care
as they can cause paint damage.
lThe use of proper tools, and the recommended
essential and available tools where specified, are
important for efficient and reliable performance of
the service repairs.lUse genuine DAEWOO parts.
lDiscard used cotter pins, gaskets, O-rings, oil seals,
lock washers and self-locking nuts. Prepare new ones
for installation. Normal function of these parts cannot
be maintained if these parts are reused.
lKeep the disassembled parts neatly in groups to
facilitate proper and smooth reassembly.
lKeep attaching bolts and nuts separated, as they
vary in hardness and design depending on the
position of the installation.
lClean the parts before inspection or reassembly.
lAlso clean the oil parts, etc. Use compressed air to
make certain they are free of restrictions.
lLubricate rotating and sliding faces of parts with oil
or grease before installation.
lWhen necessary, use a sealer on gaskets to prevent
leakage.
lCarefully observe all specifications for bolt and nut
torques.
lWhen service operation is completed, make a final
check to be sure service was done properly and the
problem was corrected.

5A-42 AUTOMATIC TRANSMISSION
POWER TRAIN SYSTEM
The Power Train System consists of:
lA torque converter with single face lock-up clutch
lFour multi-plate clutch assemblies
lTwo brake bands
lTwo one-way clutches
lPlanetary gearset
lParking mechanism
A conventional six pinion Ravigneaux compound planetary gearset is used with overdrive (fourth gear) being obtained
by driving the carrier.
The cross-sectional arrangement is very modular in nature. Four main sub-assemblies are installed within the case
to complete the build. These sub-assemblies are:
lGearset-sprag-centre support
lC1 -C2-C3-C4 clutch sub-assembly
lPump assembly
lValve body assembly
One, or a combination of selective washers are used between the input shaft flange and the number 4 bearing to
control the transmission end float. This arrangement allows for extensive subassembly testing and simplistic final
assembly during production.
A general description of the operation of the Power Train System is detailed below. Refer to table 4.1 and figure 4.1.
First gear is engaged by applying the C2 clutch and locking the 1-2 One Way Clutch (1-2 OWC). The 1-2 shift is
accomplished by applying the B1 band and overrunning the 1-2 OWC. The 2-3 shift is accomplished by applying the
C1 clutch and releasing the B1 band. The 3-4 shift is accomplished by re-applying the B1 band and overrunning the
3-4 OWC. Reverse gear is engaged by applying the C3 clutch and the B2 band.
The C4 clutch is applied in the Manual 1,2 and 3 ranges to provide engine braking. In addition, the C4 clutch is also
applied in the Drive range for second and third gears to eliminate objectionable freewheel coasting. The B2 band is
also applied in the Manual 1 range to accomplish the low-overrun shift.
Both the front and rear servos are dual area designs to allow accurate friction element matching without the need for
secondary regulator valves. All the friction elements have been designed to provide low shift energies and high static
capacities when used with the new low static co-efficient transmission fluids. Non-asbestos friction materials are used
throughout.
Gear
First
Second
Third
Fourth
Reverse
Manual 1Gear
Ratio
2.741
1.508
1.000
0.708
2.428
2.741C1
X
XC2
X
X
X
X
XC3
XC4
X
XB1
X
X
XB2
X
X1-2
OWC
X3-4
OWC
X
X
XLU
CLUTCH
X*
X ELEMENTS ENGAGED
* For Certain Vehicle Applications, Refer to the Owner's Manual. Table 4.1 - Engaged Elements vs Gear Ratios

5A-98 AUTOMATIC TRANSMISSION
Rear Band Assembly
To assemble the rear band assembly proceed as follows:
1. Check the rear band for any cracks or damage along the
lining and metal backing.
2. Install the reaction anchor strut into the main case, without
shims.
Notice
If fitting a new band, soak the new band in automatic
transmission fluid (or a minimum of five minutes prior to
assembly.
3. Carefully install the rear band into the transmission case
and ensure that it is properly fitted in the case.
4. Position the apply strut on the rear band then engage the
apply strut in the servo lever.
5. Install the cam plate and tighten the screws to specification.
Figure 8.19 - Thrust Bearing and Washer LocationsFigure 8.18 - Rear Servo and Band

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

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

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.

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.