lock SSANGYONG MUSSO 2003 Service Manual

4F-22 ANTILOCK BRAKE SYSTEM Pressure Decreased
1 Master Cylinder
2 Hydraulic Unit
3 Damping Chamber
4 Return Pump
5 Return Pump Motor6 Accumulator Chamber
7 Inlet Valve for Each Wheel
8 Outlet Valve for Each Wheel
9 Front Wheel
10 Rear Wheel

ANTILOCK BRAKE SYSTEM 4F-23
Pressure Maintained
1 Master Cylinder
2 Hydraulic Unit
3 Damping Chamber
4 Return Pump
5 Return Pump Motor6 Accumulator Chamber
7 Inlet Valve for Each Wheel
8 Outlet Valve for Each Wheel
9 Front Wheel
10 Rear Wheel

4F-24 ANTILOCK BRAKE SYSTEM ABS/ABD 5.3 Pressure Increased
1 Master Cylinder
2 Hydraulic Unit
3 Damping Chamber
4 Return Pump
5 Return Pump Motor
6 Accumulator Chamber7 Inlet Valve for Each Wheel
8 Outlet Valve for Each Wheel
9 Wheel
10 Prime Valve (ASV) 11 Pilot Valve (USV)
12 Check V alve
13 ISD (Integrated Suction Damper)

ANTILOCK BRAKE SYSTEM 4F-25
Pressure Decreased
1 Master Cylinder
2 Hydraulic Unit
3 Damping Chamber
4 Return Pump
5 Return Pump Motor
6 Accumulator Chamber7 Inlet Valve for Each Wheel
8 Outlet Valve for Each Wheel
9 Wheel
10 Prime Valve (ASV) 11 Pilot Valve (USV)
12 Check V alve
13 ISD (Integrated Suction Damper)

4F-26 ANTILOCK BRAKE SYSTEM Pressure Maintained (Hold)
1 Master Cylinder
2 Hydraulic Unit
3 Damping Chamber
4 Return Pump
5 Return Pump Motor
6 Accumulator Chamber7 Inlet Valve for Each Wheel
8 Outlet Valve for Each Wheel
9 Wheel
10 Prime Valve (ASV) 11 Pilot Valve (USV)
12 Check V alve
13 ISD (Integrated Suction Damper)

SECTION 4G
PARKING BRAKE
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4G-1General Specifications . . . . . . . . . . . . . . . . . . 4G-1
Fastener Tightening Specifications . . . . . . . . . 4G-1
Component Locator . . . . . . . . . . . . . . . . . . . 4G-2 TABLE OF CONTENTS
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 4G-2
Maintenance and Repair . . . . . . . . . . . . . . . 4G-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4G-3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 4G-3
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Parking Brake Lever Bolt Cable Mounting Bracket Bolt
N 

 m
8 - 18 8 - 18
FASTENER TIGHTENING SPECIFICATIONS
Application
Type
Operating Type
Description
Mechanically Operated Rear Wheel Expansion Manual

SECTION 5A
AUTOMATIC TRANSMISSION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5A-2
Model Part Numbers and Applications . . . . . . 5A-2
Model Specifications . . . . . . . . . . . . . . . . . . . . 5A-2
Clutch Pack Details . . . . . . . . . . . . . . . . . . . . . 5A-3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5A-4
Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5A-4
Schematic and Routing Diagrams . . . . . . . . 5A-5
TCU Circuit (Diesel) . . . . . . . . . . . . . . . . . . . . 5A-5
TCU Circuit (Gasoline) . . . . . . . . . . . . . . . . . . 5A-6
Shift Pattern Diagram . . . . . . . . . . . . . . . . . 5A-7
661LA Normal Mode . . . . . . . . . . . . . . . . . . . . 5A-7
661LA Power Mode . . . . . . . . . . . . . . . . . . . . 5A-8
662LA Normal Mode . . . . . . . . . . . . . . . . . . . . 5A-9
662LA Power Mode . . . . . . . . . . . . . . . . . . . 5A-10
662LA Low Mode . . . . . . . . . . . . . . . . . . . . . 5A-11
E32 Power Mode . . . . . . . . . . . . . . . . . . . . . 5A-12
E32 Normal Mode . . . . . . . . . . . . . . . . . . . . . 5A-13
E32 Low Mode . . . . . . . . . . . . . . . . . . . . . . . 5A-14
E23 Power Mode . . . . . . . . . . . . . . . . . . . . . 5A-15
E23 Normal Mode . . . . . . . . . . . . . . . . . . . . . 5A-16
E23 Low Mode . . . . . . . . . . . . . . . . . . . . . . . 5A-17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . 5A-18
Operator Interfaces . . . . . . . . . . . . . . . . . . 5A-20
Gear Select Lever Operation . . . . . . . . . . . . 5A-20
Driving Mode Selector . . . . . . . . . . . . . . . . . 5A-21
Control Systems . . . . . . . . . . . . . . . . . . . . . 5A-22
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-22
Electronic Control System . . . . . . . . . . . . . . . 5A-22
Hydraulic Control System . . . . . . . . . . . . . . . 5A-31
Power Train System . . . . . . . . . . . . . . . . . . 5A-42
Torque Converter . . . . . . . . . . . . . . . . . . . . . 5A-43
Clutch Packs . . . . . . . . . . . . . . . . . . . . . . . . . 5A-44Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-45
One Way Clutches . . . . . . . . . . . . . . . . . . . .
5A-45
Planetary Gear Set . . . . . . . . . . . . . . . . . . . . 5A-45
Parking Mechanism . . . . . . . . . . . . . . . . . . . 5A-46
Power Flows . . . . . . . . . . . . . . . . . . . . . . . . 5A-47
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-47
Power Flow - Park and Neutral . . . . . . . . . . . 5A-48
Power Flow - Reverse . . . . . . . . . . . . . . . . . . 5A-49
Power Flow - Manual 1 . . . . . . . . . . . . . . . . . 5A-50
Power Flow - Drive 1 . . . . . . . . . . . . . . . . . . . 5A-51
Power Flow - Drive 2 and Manual 2 . . . . . . . 5A-52
Power Flow - Drive 3 and Manual 3 . . . . . . . 5A-54
Power Flow - Drive 3 Lock Up and Manual
3 Lock Up . . . . . . . . . . . . . . . . 5A-56
Power Flow - Drive 4 (Overdrive) . . . . . . . . . 5A-57
Power Flow - Drive 4 Lock Up . . . . . . . . . . . . 5A-59
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-60
Diagnostic System . . . . . . . . . . . . . . . . . . . . 5A-60
Mechanical Tests . . . . . . . . . . . . . . . . . . . . . 5A-69
Self Diagnosis Test . . . . . . . . . . . . . . . . . . 5A-75
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 5A-79
Hydraulic System . . . . . . . . . . . . . . . . . . . . . 5A-79
Transmission Fluid Test Procedure . . . . . . . . 5A-79
Electronic Adjustments . . . . . . . . . . . . . . . . . 5A-80
Maintenance and Repair . . . . . . . . . . . . . . 5A-82
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 5A-82
Removal and Installation of Transmission . . . 5A-82
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5A-85
Rebuild Warnings . . . . . . . . . . . . . . . . . . . . . 5A-85
Disassembly Procedure . . . . . . . . . . . . . . . . 5A-85
Assembly Procedure . . . . . . . . . . . . . . . . . . . 5A-94
Front and Rear Band Adjustment . . . . . . . . 5A-128

5A-4 AUTOMATIC TRANSMISSIONSPECIAL TOOLS
SPECIAL TOOLS TABLE
Part Number
0555 - 332083 0555 - 3360460555 - 3362560555 - 3362570555 - 336258 0555 - 336259 0555 - 3362600555 - 3362610555 - 3362620555 - 336263 0555 - 336264 0555 - 3362650555 - 3362660555 - 3362670555 - 336268 0555 - 336269 0555 - 3362700555 - 332895Description
Solenoid / Thermistor, Electronic Tester
Solenoid, Bench Tester
Transmission Bench Cradle Pump Puller
Pin Remover / Installer Tool (Cross Shaft / Detent Lever)Clutch Spring CompressorClutch Pack Clearance Kit
Seal Removal Tool (Cross - Shaft) Oil Seal Dolly (Cross - Shaft)Assembly BulletSeal CompressorPin Press Seal Dolly
Alignment ToolPump Seal DollyEnd Float AdaptorEnd Float Shaft
Locknut Crimping Tool (W-Car Only)

5A-18 AUTOMATIC TRANSMISSIONINTRODUCTION
The BTR Automotive Model 74 Four Speed Automatic Transmission is an electronically controlled overdrive four
speed unit with a lock-up torque converter. The lock-up torque converter results in lower engine speeds at cruise and
eliminates unnecessary slippage. These features benefit the customer through improved fuel economy and noise
reduction. Refer to table 1.1 for details of power, torque and configuration.
Of primary significance is the transmission control unit (TCU) which is a microprocessor based control system. The
TCU utilizes throttle position, rate of throttle opening, engine speed, transmission output speed, transmission sump
temperature, gear selector position and mode selector inputs, and in some applications a ‘kickdown’ switch to control
all shift feel and shift schedule aspects.
The TCU drives a single proportional solenoid multiplexed to three regulator valves to control all shift feel aspects.
The output pressure of this solenoid is controlled as a function of transmission sump temperature to maintain consistent
shift feel throughout the operating range.
Shift scheduling is highly flexible, and several independent schedules are programmed depending on the vehicle.
Typically the ‘NORMAL’ schedule is used to maximise fuel economy and driveability, and a ‘POWER’ schedule is used
to maximise performance. ‘WINTER’ schedule is used to facilitate starting at second gear.
Figure 1.1 details the differences between conventional and electronic transmission control systems.
Max Torque (Nm)
320 Configuration
260 mm Torque Converter Wide Ratio Gear Set
Splined Output for Transfer CaseMin Torque (Nm) 160
Model
M74 4WD
Transmission
Table 1.1 - M74 Torque, Power and Configuration

AUTOMATIC TRANSMISSION 5A-21
Downshift Type
RANGE ‘1’ (MANUAL ‘1’):
RANGE ‘2’ (MANUAL ‘2’):
RANGE ‘3’ (MANUAL ‘3’):
RANGE ‘D’ (DRIVE):
RANGE ‘N’ (NEUTRAL):
RANGE ‘R’ (REVERSE):
RANGE ‘P’ (P ARK):Inhibited Above
First gear operation only with inhibited engagement as a function of vehicle speed. Engine braking is applied with reduced throttle.
First and second gear operation with inhibited engagement of second gear, as
a function of vehicle speed. Engine braking is applied with reduced throttle.
First, second and third gear operation with an inhibited third gear engagement
at high vehicle speed. Refer to the vehicle owner’ s manual.Engine braking is applied with reduced throttle.
First, second, third and fourth gear operation. First to second (1-2), first to third
(1-3), second to third (2-3), second to fourth (2-4), third to fourth (3-4), fourth
to third (4-3), fourth to second (4-2), third to second (3-2), third to first (3-1)
and second to first (2-1), shifts are all available as a function of vehicle speed,throttle position and the time rate of change of the throttle position (forced
downshift). Lockup clutch may be enabled in 3rd and 4th gears depending on
vehicle type. Refer to the owner’ s manual.
Rear band applied only, with inhibited engagement as a function of vehicle
speed, engine speed and throttle position. The inhibitor switch allows the en-gine to start.
Reverse gear operation, with inhibitor engagement as a function of vehicle
speed, engine speed and throttle position. The inhibitor switch enables reverse lamp operation.
Rear band applied only, with inhibited engagement as a function of vehicle
speed, engine speed and throttle position. The transmission output shaft is
locked. The inhibitor switch allows the engine to start.
Table 2.1 - Gear Selections DRIVING MODE SELECTOR
The driving mode selector consists of a mode selection switch and indicator light. The driving mode selector is
located on the centre console. See figure 2,1.
The schedules available to be selected vary with vehicle types. Typically the driver should have the option to select
between ‘NORMAL’ , ‘POWER’ or ‘WINTER’ modes.
When ‘NORMAL’ mode is selected upshifts will occur to maximise fuel economy and the indicator lights remain
extinguished. When ‘POWER’ mode is selected upshifts will occur to give maximum performance and the ‘POWER’
mode indicator light is swi tched on. When ‘WINTER’ mode is selected, starting at second gear is facilitated, the
‘WINTER’ mode indicator light is switched on and the ‘POWER’ mode indicator light is switched off.
Refer to the vehicle owner ’ s manual for specific modes for each vehicle type.