automatic transmission SSANGYONG MUSSO 2003 Service Manual

5A-108 AUTOMATIC TRANSMISSION
12. Install the circlip.
13. Check the C3 clutch clearance (refer to figure 8.29) usingspecial tool No.0555-331900 in the following manner (weight only).
a. Place the weight on the pressure plate and measure
the distance from the end of the cylinder to the top of the pressure plate.
b. Record this figure.
c. Remove the weight.
d. Lift the pressure plate up against the circlip and measure the distance from the end ofthe cylinder to the top of the pressure plate.
e. Record this figure.
f. Subtract the second reading from the first reading to obtain the clutch pack clearance.
NoticeWith the clutch pack supporting a weight of 2 kg, the clearance between the snap ring and the top of the pressure plate is to be between 1.20-1.45 mm.
14. If new friction plates are being fitted, remove the clutch pack and soak the friction elements in automatic
transmission fluid for a minimum of five minutes prior to
reassembly. NoticeThe clutch pack clearance must be taken before the elements are soaked in automatic transmission fluid. Figure 8.29 - Typical C3 Clutch Assembly
Clearance

AUTOMATIC TRANSMISSION 5A-109
Forward Sun Gear and C3 Clutch Pack Assembly
To assemble the forward sun gear and C3 clutch pack assembly
(Refer to figure 8.30), proceed as follows:
1. Fit the No. 7 needle thrust bearing assembly over the forwardsun gear, ensuring that the thrust washer is between the
bearing and the sun gear.
2. Lubricate the thrust plate with petroleum jelly and fit the thrust plate onto the reverse sun gear. Refer to figure 8.33.
3. Align and fit the C3 clutch assembly over the forward sun gear.
4. Lubricate the No. 6 needle thrust bearing with petroleum jelly and fit it to the thrust plate. Ensure the lugs on the outside diameter of the bearing fit in the thrust plate
counterbore. Refer to figure 8.19.
5. Align and fit the plastic thrust washer to the thrust plate with petroleum jelly.
Refer to to figures 8.19.
6. Install the assembly over the forward sun gear shaft against the No.6 thrust bearing.
Refer to figure 8.19.
7. Place the assembly to one side.
Figure 8.30 - Typical forward Sun Gear add C3 Clutch Assembly

5A-110 AUTOMATIC TRANSMISSION C1 Clutch Overdrive Shaft and Input Shaft Assembly Notice
1. Ensure that the snap rings are fitted correctly.
2. Check pistons for cracks, especially the C1 piston.
3. Do not mix clutch piston return springs.
4. If the C1/C2 clutch packs separate from the C3 clutch pack,make sure the No. 6 bearing doesn ’t drop out of the bearing
retainer.
To assemble the C1 clutch overdrive shaft and input shaft
assembly, proceed as follows:
1. Check the overdrive shaft grooves for any defect.
2. Coat the sealing rings, large and small, with petroleum jelly and fit them to the overdrive shaft. The sealing rings may
be held in place with a small amount of petroleum jelly.
3. Assemble the clutch plate and disc into the cylinder in the following sequence:
steel plate
friction disc
steel plate
friction disc
steel plate
steel plate - 0574-GOOGOl, 0574-000003, 0574-000004, 0574-000005, 0574-000020,
0574-000021, or friction disc -0574-000002
steel plate (selective)
friction disc
steel plate (selective)
friction disc
4. Check the clutch pack clearance using special tool No.0555- 331900. Refer to figure 8.31.Use selective plates to achieve the correct specification.NoticeThe clutch pack supporting a 2 kg weight, the dimension from the input shaft locating stop to the friction disc mustbe 0.70-0.90 mm.
5. If new friction plates are being fitted, remove the clutch pack and soak the friction elements in automatic transmission
fluid for a minimum of five minutes prior to assembly. NoticeThe clutch pack clearance must be taken before elements are soaked in automatic transmission fluid.
6. Check the fit of the C1 clutch hub on the overdrive shaft. If it is loose, the hub and shaft assembly must be replaced. Figure 8.31 - Typical C1 Clutch Assembly
Clearance

AUTOMATIC TRANSMISSION 5A-111
7. Coat the small nylon thrust spacer with petroleum jelly andinstall it over the overdrive shaft. Refer to figure 8.19.
8. Carefully fit the overdrive shaft into the C1 cylinder so as not to damage the sealing ring.
9. Fit the small bronze C1 hub thrust washer in place with petroleum jelly. Refer to figure 8.19.
10. Check the input shaft for any defect. Fit the input shaft into the cylinder and secure it with the circlip, ensuring
that the circlip is completely seated in the groove.
11. Coat the sealing rings with petroleum jelly and fit onto the input shaft.
12. Assemble the C1/C2/C4 clutch assembly to the C3 clutch and sun gear assembly. Refer to figures 8.32 and 8.33.
13. Install this assembly in the transmission case.

5A-112 AUTOMATIC TRANSMISSION
Pump Cover and Converter Support Notice
1. Do not wash the nose of solenoids in solvent.
2. Ensure that the correct ‘O’ ring is fitted for the application.
3. Do not mix up the low first blow-off and the torque converter blow-off ball springs.
4. Be careful not to damage the needle bearings on the assembly. Avoid any axial impact loads during assembly.
5. Check the transmission end float. This will help to detect any missing parts or incorrect assembly.NoticeFigure 8.35 shows the orientation of the cross- sections for figures 8.36 to 8.42.
To assemble the pump cover and converter support (refer to figures 8.34 and 8.35), proceed as follows.
1. Check the pump body for any damage, chips or irregularity. Check that the bush is firmly staked in the drive gear.
2. Install the seal flush with the front face of the pump body.
3. Lubricate the pump bush, and the drive and driven gears, with automatic transmission fluid.
4. Install the pump driven gear and the pump drive gear into the pump body.
5. Using a straight edge and thickness gauge, check that the clearance between pump face and gears is 0.04 - 0.018
mm.
6. Lubricate the pump body ‘O’ ring with automatic transmission
fluid and fit it to the pump body. Put the pump body to one side.
7. Ensure that the pump cover cavities, ports and holes are clean and free of any obstruction.
8. Lubricate all loose parts with automatic transmission fluid prior to assembly. Figure 8.34 - Pump, Cover and Converter
Support
Figure 8.35 - Pump Cover Assembly

AUTOMATIC TRANSMISSION 5A-113
9. Assemble the primary regulator valve and plunger (referto figure 8.36) to the pump cover, ensuring that the
regulator valve slides freely, then fit the regulator valve plug and ‘O’ ring.
10. Install the retaining pin.
11. Install the converter clutch regulator valve (refer to figure 8.37), plug, and ‘O’ ring.
Figure 8.36 - Primary Regulator Valve
Figure 8.37 - Converter Clutch Regulator Valve

5A-114 AUTOMATIC TRANSMISSION
13. Install the converter clutch control valve (refer to figure8.38), spring, plug, and ‘O’ ring.
14. Install the retaining pin. Refer to figure 8.39.
Figure 8.39 - Valve Retaining Plugs and Pins
Figure 8.38 - Converter Clutch Control Valve
12. Install the retaining pin. Refer to figure 8.39.

AUTOMATIC TRANSMISSION 5A-115
15. Install the C1 bias valve spring, valve, plug and ‘O’ ring.
Refer to figure 8.40.
16. Install the retaining pin. Refer to figure 8.39.
17. Install the converter release check ball and spring and the feed ball. Refer to figures 8.41, 8.42 and 8.43. Figure 8.40 - C1 Bias Valve
Figure 8.41 - Converter Relief Ball and Spring Figure 8.42 - Peed Ball
Figure 8.42 - Feed Ball

5A-116 AUTOMATIC TRANSMISSION
18. Install the gasket on the pump cover.
19. Install the cover plate, solenoid 7 with the retainer and thesolenoid wiring retainer to the pump cover, ensuring that
the periphery of the cover plate is flush with the periphery
of the pump cover. Refer to figure 8.34.
Tighten the screws to specification in the order (1-5), shown in figure 8.44.
24. Install the pump and cover assembly over the input shaft being careful not to damage the sealing rings. Tighten the
pump cover to case bolts to specification. Refer to figure 8.45.
20. Tighten the solenoid 7 screw. Refer to figure 8.39.
Notice Check that neither the wiring nor the connector protrudes
excessively, in order that at assembly neither the wiringand the connector contacts or rubs on the input shaft or
the C1/C2 clutch cylinder.
21. Assemble the pump to the pump cover.
Tighten all bolts and the crescent screw finger tight,
ensuring that the pump is flush against the pump cover.
Tighten the bolts and the screw to specification in the order
(A - F), shown in figure 8.44.
22. Install the pump to transmission case gasket onto the case.
23. Fit the ‘O’ ring to the pump cover outer diameter.Figure 8.44 - Pump Bolt Tightening Sequence
Figure 8.45 - Tightening Sequence Pump to
Case

AUTOMATIC TRANSMISSION 5A-117
25. Check that the transmission end float is set to the tolerancestated in section 9.2. Refer to figure 8.46. If the unshimmed
end float clearance is greater than specification, shims
are to be placed between the No. 4 bearing and the input
shaft bearing surface. Refer to figure 8.19. If the end float
clearance is less than 0.5 mm then the transmission has
been assembled incorrectly or the parts are out of specification.
26. Perform the following steps to check the end float : a. Attach a dial indicator to the front of the transmissioncase with the stylus resting on the end of the input shaft.
b. Apply a force of approximately 250 newtons or 25 kg to the input shaft.
c. Zero the dial indicator.
d. Place a small lever behind the forward clutch cylinder and lever the cylinder forward.
e. The measurement recorded on the dial indicator is the transmission end float or clearance between the No.4
bearing and the converter support tube.
27. On completion of this procedure, adjust the front and rear bands to specifications detailed in section 8.4.
Figure 8.46 - Gear Train End Float Check