lock SSANGYONG MUSSO 2003 Service Manual

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-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 andCentre 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

5A-106 AUTOMATIC TRANSMISSION
29. Align the tangs and fit the nylon thrust washer onto theC4 hub. Refer to figure 8.27.
30. Align and fit the C4 hub to the C2 clutch and the OWC assembly.
31. Check the rotation of the C2 hub. While holding the C4 hub, the C2 hub should rotate in the clockwise
direction and lockup in the anti-clockwise direction when
viewed from the C2 hub. Refer to figure 8.27.
Figure 8.27 - C2 - Hub Rotation
32. Apply petroleum jelly to the No. 5 thrust bearing and fitit to the C4 hub. Refer to figure 8.19.
33. Remove the C2 clutch plates from the clutch cylinder.
34. Fit the thrust plate over the cylinder inner hub. Refer to figures 8.24 and 8.19.
35. Engage the C2/C4 clutch hub assembly in the C4 clutch plates.
36. Install the C2 clutch plates.
37. Install the C3 hub and secure it with the circlip, ensuring that the circlip is firmly seated in its groove.Refer to figure 8.32. Figure 8.26 - Typical C2 Clutch Pack Clearance
26. Check the clutch pack clearance using only the weight
from tool No.0555-331900. Refer to figure 8.26.NoticeWith the clutch pack supporting a 2 kg weight, the dimension from the C3 clutch hub locating step to the friction plate is to be between 0.80-1.05 mm.
27. 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. NoticeThe clutch pack clearance must be taken before the
elements are soaked in ATF.
28. Lubricate and fit the 3-4 OWC and end caps to the C2 hub.

5A-122 AUTOMATIC TRANSMISSION
15. Install solenoid 6 plunger, spring and retaining pin.
16. Position the third feed ball (large nylon) in the valve bodyand install the solenoid 5 filter and the solenoid 6 filter.
Refer to figures 8.5 and 8.56.
17. Check the separator plate for burrs and damage. Repair or replace the separator plate as necessary.
18. Check the upper and lower valve body gaskets for damage. Replace the gaskets as necessary.
19. Install the lower valve body gasket on the lower valve body.
20. Install the reverse lockout valve, spring, plug and retainer plate. Ensure that the valve is correctly oriented. Refer to figure 8.57.
Figure 8.57 - Reverse Lockout Valve
21. Position the five nylon ball checks in the upper valve body.Refer to figure 8.48.
22. Fit the upper valve body gasket. Install the separator plate over the upper valve body.

AUTOMATIC TRANSMISSION 5A-127
Torque Converter and Housing Assembly
To assemble the torque converter and housing assembly, proceed as follows.
1. Locate the torque converter housing on the transmissionmain case.
2. Install and tighten the securing bolts to specification. NoticeAll the hardware must be correctly installed and torqued to specification.
3. Fit the converter ensuring that the tangs are engaged in the pump gear. Ensure that the tangs do not contact thepump seal.
Figure 8.1 - Torque Specifications
Torque Specifications
Torque converter housing to case Extension housing to case Rear servo coverPan to caseInhibitor switch to caseCooler connectors
Transmission filler plug Output flange lock nut (RWD models)Centre support to caseCam plate to case (parking pawl)
Valve body to case Upper valve body to lower valve bodyON/OFF solenoid retainers
Variable pressure solenoid retainerLine pressure plug Detent spring Pump cover to casePump cover plate to pump coverPump to pump adaptorPump cover plate to crescent Adaptor to case N

m
54 - 68 54 - 6825 - 35 4 - 6
2.3 - 3.4 30 - 3530 - 35
100 - 110
20 - 27 16 - 228 - 13
11 - 16 8 - 12 8 - 12
4 - 7
20 - 2224 - 3413 - 1624 - 27 13 - 16 25 - 35

Model
Type Gear Ratio Oil Weight (Dry)SECTION 5B
MANUAL TRANSMISSION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5B-1 General Specifications . . . . . . . . . . . . . . . . . . 5B-1
Fastener Tightening Specifications . . . . . . . . . 5B-2
External View . . . . . . . . . . . . . . . . . . . . . . . . 5B-3 Gear T rain . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-3
Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5 Will not Shift (Control Lever Moves) . . . . . . . . 5B-5 Hard Shift or Control Lever Will not Move Into
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5
Gears Crash When Shifting . . . . . . . . . . . . . . 5B-5
Transmission Jumps Out . . . . . . . . . . . . . . . . . 5B-6
Transmission Locked in One Gear . . . . . . . . . 5B-6
Transmission Noise . . . . . . . . . . . . . . . . . . . . . 5B-6
Transmission Leakage . . . . . . . . . . . . . . . . . . 5B-7Diagnosis Table . . . . . . . . . . . . . . . . . . . . . . .
5B-8
Component Locator . . . . . . . . . . . . . . . . . . . 5B-9
Maintenance and Repair . . . . . . . . . . . . . . 5B-11
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 5B-11 Shift Control Cable . . . . . . . . . . . . . . . . . . . . 5B-11
Transmission . . . . . . . . . . . . . . . . . . . . . . . . 5B-14
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17 Major Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17
Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-27
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-32
Counter Shaft . . . . . . . . . . . . . . . . . . . . . . . . 5B-34
Extension Housing . . . . . . . . . . . . . . . . . . . . 5B-35
Shift Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-36
Inspection of Components . . . . . . . . . . . . . . 5B-40
Pre-Installation Checks . . . . . . . . . . . . . . . . . 5B-45
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Description
T5WC
Floor Change
3.97 : 1 2.34 : 11.46 : 11.00 : 10.85 :1
3.71 : 1
ATF DEXRON II / III 3.4 L
Check : Every 15,000km, Replace : Every 50,000km
33kg
1st
2nd 3rd
4th 5th
Reverse
Specification
Capacity(litre)
Change Interval
Notice Add LUBRIZOL (280cc) in oil after overhauling.

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-8 MANUAL TRANSMISSION1 Shift Hop-out 2 Shift Gear Crash 3 Shift Block-out 4 Hard Shift 5 Noise in Reverse Gear6 Noise in 5th Gear 7 Noise in 4th Gear 8 Noise in 3rd Gear 9 Noise in 2nd Gear 10 Noise in 1st Gear
11 Noise in All Speeds 12 Leak at Transmission Rear Part 13 Leak at Transmission Center Part 14 Leak at Transmission Front
DIAGNOSIS TABLE
Condition
Possible Faulty Part
Transmission Case Extension HousingShift Cover / Shift ShiftShift Control LeverInput Bearing RetainerInput Gear Set3rd Speed Gear Set2nd Speed Gear SetReverse Speed Gear Set1st Speed Gear Set5th Speed Gear SetClutch Housing and Release DeriveCrankshaft Pilot Bushing and Release BearingInput BearingMain Shaft Input BearingMain Shaft Thrust Bearing3rd Speed Gear Bearing2nd Speed Gear Bearing1st Speed Gear BearingReverse Idler Gear BushingCounter Shaft Front BearingCounter Shaft Rear BearingCounter Shaft Thrust Bearing5th Speed Drive Gear Bearing
Slip Yoke Bushing
Slip Yoke SealSpeedometer Drive / Driven GearsSpeedometer Driven Gear HousingInput Shaft Seal1 - 2 Synchronizer Assembly3 - 4 Synchronizer Assembly5th Synchronizer AssemblyRing Oil SealT/C Front Face