wheel SSANGYONG MUSSO 2003 Service Manual

5A-42 AUTOMATIC TRANSMISSIONPOWER TRAIN SYSTEM
The Power Train System consists of: A torque converter with single face lock-up clutch
Four multi-plate clutch assemblies
Two brake bands
Two one-way clutches
Planetary gearset
Parking 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: Gearset-sprag-centre support
C1 -C2-C3-C4 clutch sub-assembly
Pump assembly
Valve 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 finalassembly 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 ThirdFourth
Reverse
Manual 1 Gear
Ratio 2.741 1.508 1.0000.7082.4282.741 C1
XX C2
X X XX X C3
X C4
X X B1
X X X B2
X X 1-2
OWC X 3-4
OWC X XX LU
CLUTCH
X*X
ELEMENTS ENGAGED
* For Certain Vehicle Applications, Refer to the Owner's Manual.
Table 4.1 - Engaged Elements vs Gear Ratios

5A-44 AUTOMATIC TRANSMISSION CLUTCH PACKS
There are four clutch packs (refer to figure 4.3). All clutch packs are composed of multiple steel and friction plates. C1 CLUTCHWhen applied, this clutch pack allows the input shaft to drive the planet carrier.
This occurs in third and fourth gears.C2 CLUTCH When applied this clutch pack allows the input shaft to drive the forward sun gear via the 3-4 OWC.
This occurs in all forward gears.C3 CLUTCH When applied this clutch pack allows the input shaft to drive the reverse sun gear. This only occurs in
reverse gear.C4 CLUTCH When applied this clutch provides engine braking on overrun. This occurs in Manual 1, 2 and 3 and
also Drive 2 and Drive 3 to prevent objectionable free wheel coasting.
Figure 4.3 - Clutch Packs

5A-60 AUTOMATIC TRANSMISSIONDIAGNOSIS
DIAGNOSTIC SYSTEM Recommended T est Equipment and Procedure
The test equipment is designed to be used with the control modules in all vehicles. The components used in the transmission application are: Multi Function Tester, and
Appropriate vehicle for testing.
Multi Function Tester (MFT)
The MFT is programmed with the special vehicle diagnostic software that allows selection of the unit under test.
The program allows the proper communication to the Transmission Control Unit (TCU).
It then requests information from the user via a menu system to select the required set up.
Examples are viewing codes, clearing error codes, and real-time operation. Set up and operation instructions are detailed in the user manual.
This equipment can be used by trained personnel such as technicians and mechanics to diagnose electronic and
wiring problems relating to the vehicle transmission. Information that is available includes engine and road (shaft)
speed, transmission oil temperature, throttle position, solenoid/gear status and gear lever position. Current andstored faults detected by the electronics are also available.
TCU Pin Description The TCU pin descriptions are listed in table 6.1.1. The wiring loom pins are shown in figure 6.1.1
Pin
No. 1 2 3 4 5 6 7 8Identification
Common Ground Do not use Mode Indicator Lamp -‘ Winter ’
Gear Position ‘Park ’
LampGear Position ‘Reverse ’
LampGear Position ‘Neutral ’
LampDo not useEngine Speed Input
Sensor (-Ve) Type
GND -
OP OP OP OP
-
IP Description
Main power ground (or the module. Connects
directly to the battery negative terminal. Indicates ‘WINTER ’ mode shift schedule is se-
lected.
Drives the jewel in the instrument cluster to in-dicate ‘PARK ’ gear lever position.
Drives the jewel in the instrument cluster to in- dicate ‘REVERSE ’ gear lever position.
Drives the jewel in the instrument cluster to in- dicate ‘NEUTRAL ’ gear lever position.
Flywheel/Ring gear pulses to indicate engine speed.
4WD
(Diesel)
O O




4WD
(Gas)
O O O






Table 6.1.1 - TCU Pin Description

AUTOMATIC TRANSMISSION 5A-61
Pin
No. 9 10
11
12 13 14 1516 17 1819 20 21 22 2324 25 26 27 28 29 30Identification
Mode Indicator Lamp - ‘ Power ’
Throttle Position Sensor Output as Pulse Width Modulation for TODAir Conditioner Input SignalKickdown Switch Mode Switch
Transfer Case Input (High) -4WD Lamp High Ignition Switch Do not use Gear Position ‘1’ Lamp/
Gear Position Code 1
*Gear Position ‘2’ Lamp/
Gear Position Code 2* Gear Position ‘3’ Lamp/
Gear Position Code 3* Gear Position ‘Drive ’
Lamp/ Gear Position Code 4*CAN (-ve)CAN (+ve) K-line Communication Link Engine Speed InputSensor (+ve)Road Speed Pulses Shaft Speed Sensor SignalThrottle Position Sensor -GroundThrottle Position Sensor - Reference Throttle Position Sensor -Input Signal
Transfer(or Case Input
(Low) - 4WD Lamp Low Type
OP OP
-
IP IP IP IP
-
OPOPOP OP
I/O
I/O
I/O IP
OP
IP
GND
REF IP IP Description
Indicates ‘POWER ’ mode shift schedule is se-
lected.
Provides an analogue signal of the throttle po- sition for the T orque on Demand (T OD) Con-
trol Module. Input
Switch to indicate when a kickdown is required
at high throttle position. Switch to select ‘NORMAL ’, ‘POWER ’ or ‘WIN-
TER ’ shift schedule.
Voltage varies from OV to 12V. Switch to indicate 4WD ’HIGH RANGE ’ is se-
lected.
Ignition power is used as the main power source
to drive the unit and the solenoids.
Drives jewel in the instrument cluster to indi- cate gear leverposition ’1'. Drives jewel in the instru-
ment cluster to indicate gear lever position ’2'. Drives jewel in the instru-
ment cluster to indicate gear lever position’3'.
Drives jewel in the instrument cluster to indi- cate ‘ DRIVE ’. gear lever position.
CAN low side bus communication (CANL).
CAN high side bus communication (CANH).
Diagnostic information and vehicle coding.
Flywheel/Ring gear pulses to indicate engine speed.
Road speed signals derived from shaft speedsensors.
This sensor transmit shaft speed signal to the TCU. Throttle position sensor ground. This is the 5V reference voltage supply gener-
ated by the unit for the throttle position sensor.
This sensor is a resistance potentiometer indi-
cating throttle position.
Voltage varies 0V to 5V.Switch to indicate 4WD ’LOW RANGE ’ is se-
lected.
4WD
(Diesel)
O O O O



4WD
(Gas)
O O O O O O OO

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 TRANSMISSIONCheck
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 GEARAction
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 forwear 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 crankshaftalignment.Noisy transmission bearing. Noisy gears. TRANSMISSION NOISEAction
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-46 MANUAL TRANSMISSION
Check the housing face alignment.
- Place the dial indicator on the housing face.
- By rotating the crankshaft one revolution, record the
dial indicator reading.
NoticeIf the reading is greater than 0.010 inch, insert the shim between the engine and clutch housing and adjust thealignment.
5. Check the following parts : Pressure plate spring assembly
Disc
Flywheel
Input shaft pilot bearing
Notice
Replace the excessively worn parts.
6. Lubricate the clutch release bearing bore, fork pivot head during assembly.

5C-4 CLUTCHChecks
Oily Facing Hard or Faulty Facing
Burnt Torsion Spring Faulty Pressure Plate Bent Clutch Diaphragm SpringHard or Bent FlywheelEngine Mounts Loose or Burnt Lever Action
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 LiningDirty or Burred Splines on Input Shaft or Clutch DiscDamaged Clutch Pressure Plate Checks
Vibration or Excessive Run-out of DiscRust or Wear of Disc Spline Oily Facing Damaged Diaphragm SpringExcessive Clutch Pedal Free play DIAGNOSIS
CLUTCH SLIPS
Checks
Excessive Wear of Facing Hard or Oily FacingDamaged Pressure Plate or FlywheelDamaged or Burnt Diaphragm SpringClutch Pedal Free play Insufficient Faulty Operation of Clutch Pedal Worn or Damaged Clutch Disc Action
Replace
Repair or Replace ReplaceReplaceAdjust
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

5C-10 CLUTCH Removal & Installation Procedure
1. Remove the starter motor. Install the special tool to theflywheel through the starter motor mounting holes.
Tightening Torque 47 Nm
Engine Lock 602 589 00 40 00
2. Unscren the release cylinder mounting bolts and remove the release cylinder. Installation Notice
3. Unscrew the clutch housing bolts and remove the clutch housing, release fork and release bearing.Installation Notice
4. Insert the centering pin into the clutch spline. Loosen the clutch cover bolts 1/2 turn in crisscross sequence until the spring tension is released. Notice
Do not remove the bolts at a time, or clutchcover can be damaged or deformed.
Centering Pin 661 589 00 15 00
Tightening Torque 30 - 40 Nm

CLUTCH 5C-11
5. Unscrew the bolts and remove the clutch cover, pressure
plate and clutch disc. NoticeBe careful not to drop the pressure plate and clutch disc.Installation Notice
Tightening Torque 21 - 27 Nm
6. Installation should follow the removal procedure in the reverse order. Notice
Before installation, clean oil and grease on the flywheel surface.
Do not clean the clutch disc and release bearing insolvent.