automatic transmission SSANGYONG MUSSO 2003 Service Manual

5A-88 AUTOMATIC TRANSMISSION
8. Detach the No.7 solenoid wire from the front of the case.
9. Remove the parking pawl pivot pin and the pawl and springfrom the case.
10. Remove the shaft and the rear servo lever.
11. Remove the rear servo cover and piston assembly.
12. Remove the B1R circlip, valve and spring.
13. Remove both band adjustment shims.
14. Inspect the output shaft bushing in the case and replace if necessary.
15. Inspect cooler line fittings and replace as necessary.
16. Inspect the case for damage.
17. To remove the park rod lever: Remove the circlip from the inner end of the pivot shaft and tap the outer end of the
shaft until it moves free from the case, then using a wide
shallow tapered drift as a wedge, drive the pin out fromthe inside of the case and remove the lever and spring. NoticeDo not remove the park rod lever unless absolutely
necessary.

AUTOMATIC TRANSMISSION 5A-89
Forward Clutch Cylinder
To remove the forward clutch cylinder, refer to figure 8.4,
proceed as follows.
1. Place the assembly in a horizontal position.
2. Remove the thrust bearing and adjustment shims from the input shaft.
3. Remove the circlip from the front of the clutch cylinder and remove the input shaft.
4. Remove the overdrive shaft and the C1 clutch hub assembly from the clutch cylinder.
5. Remove the C1 clutch plates from the cylinder.
6. Remove the circlip retaining the C3 clutch hub in the rear of the clutch cylinder and remove the hub.
7. Remove the C2/C4 clutch hub assembly and remove the thrust bearing from the C4 hub.
8. Remove the C2 clutch plates.
9. Invert the clutch cylinder and remove the C4 clutch sleeve, clutch plates and the two wave washers. The 3-4 one way
clutch is located between the C2 and C4 clutch hubs, andthe hubs may be separated by rotating one hub clockwise
and withdrawing it from the other.
Figure 8.4 - Forward Clutch Cylinder Assembly

5A-90 AUTOMATIC TRANSMISSION
10. Remove the thrust block from the C4 clutch cylinder hub.Notice
Make sure that the spring keeper is not caught in the circlip
groove, and that all the spring pressure is released, before
removing the tool.
11. Mount the clutch cylinder on tool No.0555-331899 with the C2/C4 end uppermost and compress the piston return
spring. Remove the spring retaining circlip. Release the
tool and remove the circlip, keeper and spring.
12. Invert the clutch cylinder on the compressor tool and remove the C1 clutch piston return spring in a similar
manner.
13. To remove the clutch pistons from the clutch cylinder, apply
air pressure to the apply ports in the bore of the cylinder.

AUTOMATIC TRANSMISSION 5A-91
C3 Clutch Cylinder
To remove the C3 clutch cylinder, proceed as follows:
1. Remove the forward sun gear and thrust bearing from theC3 clutch cylinder.
2. Remove the nylon thrust bearing, bearing support, needle thrust bearing and thrust block from the clutch cylinder hub.
3. Mount the clutch assembly on tool No.0555-331899 and
compress the piston return spring. Remove the circlip and release the spring. Notice
Make sure that the spring keeper has not been caught in
the circlip groove, and that all spring pressure has been
released, before removing the tool.
4. Remove the tool, circlip, keeper and spring.
5. Remove the sealing rings from the C3 clutch cylinder.
6. Remove the clutch plate retaining circlip and remove the clutch plates.
7. To remove the clutch piston from the clutch cylinder, apply air pressure to the port between the iron sealing rings on
the bearing journals of the cylinder.
8. Remove the reverse sun gear from the cylinder.

5A-92 AUTOMATIC TRANSMISSION
Planet Carrier and Centre Support
To remove the planet carrier and centre support, proceed as follows.1. Separate the planet carrier and centre support from the output shaft. Remove the thrust bearings from the output
shaft and the planet carrier.
2. Separate the centre support from the planet carrier by rotating it anti-clockwise.
3. Lift the one way clutch from the planet carrier.
4. Remove the circlip retaining the one way clutch outer race in the planet carrier and remove the race.
5. Remove the one way clutch retainer from the planet carrier.
Pump
Note that the following valves are housed in the pump cover:
Solenoid 7
C1 bias valve
Converter clutch control valve
Converter clutch regulator valve
Primary regulator valve
To remove the pump, proceed as follows. 1. Remove the wiring loom retainer plate and remove solenoid 7 with a T30 Torx bit.
2. Remove the five washer head bolts from the cover plate using a multi-point 8 mm socket.
3. Remove the five Torx head screws from the cover plate (Torx bit No. 30). Note that the odd screw holds the pump
body to the pump body cover. Notice
Do not strike the converter support tube to loosen the
pump body.
4. Separate the pump body from the pump cover.
5. Lift the cover plate from the cover.
6. Remove the two ball check valves and one spring from the pump cover.Notice
Some of the valves and plugs are preloaded by springs
and may unexpectedly fall out of the cover when the pinsare removed.
7. Depress the plug inward and remove the retaining pin for each of the four valves.
8. Remove the four valves, plugs and springs.
9. Remove the pump gears from the pump body.
10. Remove the lip seal from the front of the pump body.

AUTOMATIC TRANSMISSION 5A-93
Valve Body
To disassemble the valve body, proceed as follows.1. Remove the detent spring and retainer plate using a T40 Torx bit.
Notice
Be aware that the manual valve will fall out of the valve body.
2. Take note of the angular relationship of the solenoid terminals to the valve body, then slide the manual valve out of the lower
valve body.
3. Remove the solenoid and valve assembly as follows: solenoid 1
solenoid 2
solenoid 3
solenoid 4
solenoid 5
solenoid 6
4. Place the valve body assembly on the bench with the upper body uppermost.
5. Remove the 24 clamping screws with a No. 30 Ton bit. Separate the upper and lower valve bodies by lifting the upper body and
the separator plate together.
6. Upper body over and place it on the bench with the separator plate uppermost.
7. Lift the separator plate and gaskets from the upper valve body.
8. Remove the five nylon check balls exposed in the valve body.
9. Remove the retainer plate, plug, spring and reverse lockout valve.
10. Remove the two filters (and the large nylon check ball) from the lower valve body. Notice Once the pins are removed, the plates are loose in the valve
body and will drop out when the valve body is turned over.
11. Remove the keeper plates and pins from the 1-2,2-3,3-4, BAR and CAR valves. The pins can be removed with a magnet.
12. Remove the 1-2,2-3 and 3-4 shift valves. Notice The plug is preloaded by the spring and may unexpectedly fall
out of the valve body.
13. Depress the 4-3 sequence valve plug and remove the keeper plate.
14. Remove the plug, valve and spring.
15. Depress the solenoid 5 valve. Remove the keeper pin and remove the valve and spring. Notice The valve is preloaded by the spring and may unexpectedly fall
out of the valve body.
16. Depress the line pressure release valve, remove the keeper pin, disc (if fitted), spring and valve.
17. Drive out the roll pin and remove the spring and ball check valve adjacent to the BAR valve.

5A-94 AUTOMATIC TRANSMISSION
ASSEMBLY PROCEDURE The transmission is assembled in modular fashion and details of assembly for each module are given under the appropriatesubject. 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 Torxbit 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 notfitted, 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 seatedin its groove.
4. Install the rear servo lever and pivot pin.
Notice The lever must pivot freely on its pin.

AUTOMATIC TRANSMISSION 5A-95
Notice
Care must be taken when applying sealant to ensure that it is
not applied between the pin and the lever.
5. Assemble the park rod lever, complete with the return springand pivot pin, applying a small amount of sealant to the
outer end of the pivot pin.Notice That the lever must pivot freely on its pin and the spring must return the park rod lever to its correct location.
6. Secure the pivot pin with the circlip. Notice The pawl must pivot freely on its pin.
7. Install the parking pawl pivot pin and spring.
8. Connect the park rod to the manual valve detent lever.Ensure the spring and cam collar is firmly installed on the rod.

5A-96 AUTOMATIC TRANSMISSION9. 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 andterminal in the pump mounting flange at the front of the case. The solenoid 7 wire is routed under the park rodand cross shaft in the case.

AUTOMATIC TRANSMISSION 5A-97
20. Install the ten pin connector in the case engaging the tangson the connector in the notches in case.
4WD MODELS ONLY
21. Route the portion of the wiring loom coming out of the case down between the inhibitor switch and the case.
Position the ten pin plug on the wiring loom bracket .