brake fluid SSANGYONG MUSSO 2003 User Guide

HYDRAULIC BRAKES 4A-3
Check
Air in Brake system Fluid LeakingExcessive Clearance Between Push Rod and M/cylinder Parking Brake is not Fully Released Incorrect Adjustment of Parking BrakeWeak Return Spring of Brake PedalIncorrect Pedal FreeplayBroken Rear Drum Brake Shoe Return Spring Lack of Lubrication
Damaged Master Cylinder Check Valve or Piston Return Spring Action
Bleeding
RepairAdjust
Repair Adjust
Replace
Repair
Replace
lubricate Replace
INCREASING PEDAL STROKE (PEDAL GOES TO FLOOR)
OR BRAKE DRAGGING
Check
Insufficient Clearance Between Push Rod and Master Cylinder Worn Brake Lining Oil or Grease on Lining Binding Parking Brake CableFaulty Auto AdjusterExcessive Lever Stroke Action
Adjust
Replace Replace ReplaceReplace
Adjust or Check Cable
POOR BRAKING OF PARKING BRAKE

HYDRAULIC BRAKES 4A-7
MAINTENANCE AND REPAIRON-VEHICLE SERVICE
BLEEDING THE BRAKES For Master Cylinder Replacement
1. Add oil after master cylinder replacement.
2. Run the engine and depress the brake pedal several times to build pressure and then keep the pedal fully depressed.
3. Loosen the screws of primary and secondary pipe at the master cylinder outlets to bleed air.
4. Repeat above step No.3 several times until there are no more air bubbles.
5. Bleed air in the system at the hydraulic unit outlet pipe and wheel if pressure building is not enough by depressing the pedal only after above air bleeding.
For Caliper and Brake Hose Replacement
1. Check the oil level from the oil reservoir and refill if necessary.
2. Run the engine and depress the pedal several times to build pressure and then keep the pedal fully depressed.
3. Connect a vinyl tube to the caliper breather and prepare a container to coentain brake oil.
4. Loosen the breather screw until there are no more bubbles.
5. Bleed air in the system at four (4) wheels in order as shown in right figure if pressure building is not enough by depressing the pedal after above air bleeding.
Tightening Torque
9 - 14 NmItem
Front Bleeder Screw
Rear Bleeder Screw
Notice
Do not reuse the bled brake fluid.
Always bleed the air after replacing brake fluid or
master cylinder, caliper, brake hose and pipe.
Always operate in normal order.

HYDRAULIC BRAKES 4A-13
Construction LCRV consists of sensing part and hydraulic control part.
1. Sensing PartIt detects the changes of vehicle height caused by vehicle load. It consists of load sensing spring and control leverwhich change according to vehicle load.
2. Hydraulic Control Part It consists of valve stem devices which controls hydraulicpressure according to load detected by sensing part.
Trouble Shooting Poor Braking Possible Cause
Air in Brake System Poor Adjustment of Sensor SpringDamaged Sensor SpringFluid Leaking from LCRV Remedy
Bleeding Adjust
Replace Replace
Possible Cause
Poor Adjustment of Sensor Spring Internal Fluid Leaking of LCRV Remedy
Adjust
Replace
Abnormal Locking

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

AUTOMATIC TRANSMISSION 5A-79
ADJUSTMENTS
HYDRAULIC SYSTEM
The procedures detailed below should be followed in the event that the self test procedure detailed in section 6, or a
defect symptom, indicates that there is a fault in the hydraulic system.
When making adjustments to the transmission, select the appropriate procedures from the following preliminary checks. Conduct a transmission fluid test procedure, refer to section 7.2.
Check the manual linkage adjustment (refer to the vehicle workshop manual).
Check engine idle speed (refer to Section 7.3).
Conduct a stall test (it is outside the scope of this publication to detail this procedure)
conduct a road test (it is outside the scope of this publication to detail this procedure).
TRANSMISSION FLUID TEST PROCEDURE
Checking Transmission Fluid Level
This procedure is to be used when checking a concern with the fluid level in a vehicle. A low fluid level will result in
gearshift loss or delay if driven when the vehicle is cold.
The vehicle is first checked for transmission diagnostic messages (refer to section 6). If the vehicle has a speedo fault
it is possible for the oil level to be low.
The vehicle is to be test driven to determine if there is an abnormal delay when selecting drive or reverse, or loss of
drive. One symptom of low oil level is a momentary loss of drive when driving the vehicle around a comer. Also when
the transmission fluid level is low, a loss of drive may occur when the transmission oil temperature is low.
If there is no loss of drive when the vehicle is driven warm and a speedo fault is registered, then fluid should be addedto the transmission.
Checking, Adding Fluid and Filling
When adding or changing transmission oil use only Castrol TQ 95 automatic transmission fluid (A TF) or other approved
fluids. The use of incorrect oil will cause the performance and durability of the transmission to be severely degraded. Do not underfill the transmission. Incorrect tilling may cause damage to the transmission. The fluid level setting
procedure is detailed below. Notice
When a transmission is at operating temperature hot transmission fluid may come out of the case if the fill plug is
removed. 9 the transmission is at operating temperature allow two hours for cooling prior to removing the plug.
1. If the vehicle is at operating temperature allow the vehicle to cool down for two, but no greater than four hours before adding transmission fluid (this will allow the transmission to be within the correct temperaturerange).
While hot the ATF level is higher and removing the plug may result in oil being expelled from the filler hole. This
will result in the level being low.
2. The transmission selector is to be in Park. Switch the engine off.
3. Raise the vehicle on a hoist (or leave over a service pit).
4. Clean all dirt from around the service fill plug prior to removing the plug. Remove the oil service fill plug. Clean the fill plug and check that there is no damage to the ‘O’ ring.
Install the filler pump into the filler hole.
5. Lower the vehicle with the filler pump still connected and partially fill the transmission.
Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission
gear selector through all positions, adding ATF until gear application is felt.

5A-80 AUTOMATIC TRANSMISSION6. Switch off the engine and raise the vehicle on the hoist, if applicable, ensuring that the vehicle is level.
7. Three minutes after the engine has stopped, but no longer than one hour, remove the filler pump, The correct level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATF to the correct level.
8. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle.
9. Tighten the transmission filler plug to specification.
Checking, Adding Fluid and Filling - Drained or Dry Transmission
To set the correct fluid level proceed as follows. 1. Set the transmission selector to Park and switch the engine off.
2. Raise the vehicle on a hoist (or leave over a service pit).
3. Clean all dirt from around the service fill plug prior to removing the plug, Remove the oil service fill plug. Clean the fill plug and check that there is no damage to the ‘O’ ring. Install the filler pump into the filler hole.
4. Lower the vehicle with the filler pump still connected and partially fill the transmission. This typically requires approximately :
a. If the transmission torque converter is empty:
9.0 litres - 4WD9.0 litres - RWD
b. If the transmission torque converter is full: 4.5 litres - 4WD4.5 litres - RWD
5. Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission gear selector through all positions, adding ATF until gear application is felt.
6. Then add an additional 0.5 litres of ATF.
7. Switch off the engine and raise the vehicle on the hoist. Remove the filler pump and replace the filler plug. The plug shall be tightened to specification.
8. The vehicle is then to be driven between 3.5 and 4.5 kilometers at light throttle so that the engine does not exceed 2500 rpm. This should result in the transmission temperature being in the range 50 to 60 °C.
9. With the engine idling, cycle the transmission selector through all gear positions with the brake applied.
10. Stop the engine. Raise the vehicle on the hoist, if applicable ensuring the vehicle is level.
11. Three minutes after the engine has stopped, but no longer than one hour, remove the filler plug. The correct level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATP to the correct level.
12. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle. Tighten the transmission Filler plug to specification.
ELECTRONIC ADJUSTMENTS Idle Speed Adjustment
Carry out the adjustments to the idle speed as detailed in the workshop manual.
Throttle Position Calibration
Should the throttle position data stored in the TCU be lost or be out of specification, as indicated by a diagnostic
trouble message, it may be re-established by the following procedure. Check that the hot engine idle speed is within specification.
Allow the engine to idle in ‘Drive ’ for 60 seconds with the air conditioner (if fitted) turned off. The closed throttle
reference point in the TCU has now been set.
Switch the engine off but leave the ignition on. Hold the accelerator pedal on the floor for 60 seconds. The wide open
throttle reference point in the TCU has now been set.

6A-2 POWER STEERING SYSTEMChecks
Damaged or Binding Steering Ball Joint Improper Preload of Steering Pinion
Damaged Wheel or TireFaulty Suspension System Checks
Worn Steering Gear Worn or Damaged Steering Ball Joint Loosened Steering Gearbox Bolts Checks
Damaged Steering Linkage
Damaged Wheel and Tire Faulty Brake System Faulty Suspension System Checks
Lack of Lubrication Abnormal Wear or Binding of Steering Ball Joint Damaged or Faulty Steering GearImproper Preload of Steering PinionFaulty Steering Shaft JointSteering Fluid Leaks Lack of Fluid or Air-in System Faulty Steering Oil PumpDamaged or Loosened Pump Drive BeltClogging Oil Line
Damaged Wheel or Tire Faulty Suspension System DIAGNOSIS
HARD STEERING
Action
Lubricate
Replace
Replace gear assembly
Adjust
Replace
Repair or replace
Replenish or bleed Replace
Adjust or replace
Repair or replace Repair or replace Repair or replace
STEERING PULLS TO ONE SIDE
Action Repair
Repair or replace Repair or replace Repair or replace
EXCESSIVE WHEEL PLAY
Action
Replace gear assembly
Replace
Retighten
POOR RETURN OF STEERING WHEEL
Action
Replace
Replace gear assembly Repair or replace Repair or replace

BODY WIRING SYSTEM 9A-11
ENGINE ROOM1 Engine Room Relay Box
1.1 Main Wiring Connector
1.2 Main Wiring Connector
1.3 Main Wiring Connector ........................................Gasoline E/G
1.4 Joint
1.5 Compressor, Condenser Fan Relay .....................Diesel E/G
1.6 Condenser Fan Relay 2
1.7 Air Conditioner Relay
1.8 Resistor with Diode .............................................. Gasoline E/G
1.9 Front Fog Lamp Relay
1.10 Condenser Fan Relay 1
1.11 Tail Lamp Relay
1.12 Horn Relay
2 Octane Selector ................................................... Gasoline E/G with HFM
3 Preheating Unit .................................................... Diesel E/G
4 Preheating Timer Unit .......................................... Diesel E/G
5 ECS Main Wiring Connector ................................ ECS
6 Brake Leveling Fluid Sensor
7 ABD Main Wiring Connector ................................ABD 5.0
7 - 1 ABS Main Wiring Connector ................................ABD 5.0
8 ABD main Wiring Connector ................................ABD 5.0
9 Engine Temperature Sensor ................................Diesel E/G
10 ABS 5.0 ECU ....................................................... ABS 5.0
10-1 ABD 5.0 Modulator ............................................... ABD 5.0
11 Front Washer Motor ............................................. Diesel E/G
12 Head Lamp Relay
13 Compressor ......................................................... Air Conditioner
14 Wheel Speed Sensor ........................................... ABS 5.0 or ABD 5.0

5-144 ELECTRICAL WIRING DIAGRAMS
2) WARNING LAMP(BATTERY CHARGE, BRAKE, OIL PRESSURE, SEAT BELT,ENGINE CHECK, AIR BAG) CIRCUIT
Main - Engine Engine - MainGenerator - EngineGenerator - Engine Generator - Engine Engine - MainEngine Main - ECM MainMain Air BagMain - T/M Main - T/M (GSL) Main - T/M (DSL)Main - T/MMain - T/MMain - ECM Main Engine
C101 (21Pin, Colorless) C104 (15Pin, Black)C106 (4Pin, Black)C107 (3Pin, Black) C108 (2Pin, Black) C109 (16Pin, Black)C111 (40Pin, Black)C203 (4Pin, Colorless)C207 (16Pin, Black) C208 (16Pin, Black) C208 (12Pin, Black)C209 (8Pin, Black)C210 (4Pin, Black) C213 (6Pin, Colorless) G101
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Under The Engine Room Fuse Block Under The Air Cleaner Housing (DSL, Turbo)Under The Air Cleaner Housing (DSL, N/Turbo)Under The Air Cleaner Housing (GSL)Under The Coolant Reservoir Tank Center The Engine Room Dash Panel Left The AudioUpper The T/CUpper The T/CUpper The T/C Upper The T/C (DSL) Upper The T/C (GSL)Beside Yhe ECM (MSE)Behind The Left Lamp
C101
W/H MAINC104
W/H ENGINE C106
W/H GENERATOR C107
W/H GENERATOR
C108
W/H GENERATOR C109
W/H ENGINE
C111
W/H ECM MAIN
C203
W/H MAIN
C207
W/H T/M C208
W/H MAIN (DSL) C209
W/H MAIN
C210
W/H MAIN C213
W/H ECM MAIN CLUSTER
BRAKE FLUID
LEVEL SWITCH
10 1
20 11
30 21
40 31
1234 5678
9 101112
13 14 15 16
321
654
11 2
29 38
28
13 2021
39 434842
C208
W/H T/M (GSL)
1234 5678
9 101112
13 14 15 16
1212
34
1234 5678
9 1011121234
5678
12 3412